JP2021133594A - Image recording device, abnormality detection control method and program - Google Patents

Abstract

To provide an image recording device, an abnormality detection control method, and a program capable of identifying an abnormality more easily.SOLUTION: An image recording device comprises a recording operation unit having a plurality of recording elements and performing recording of an image on a medium by operating the plurality of recording elements to record, and a control unit. The plurality of recording elements are grouped into a plurality of drive units. The control unit performs setting of not operating the recording elements to record for each drive unit for the original image data to be recorded, and causes the recording elements to record a missing image that is not recorded by the recording elements of some of the set drive units.SELECTED DRAWING: Figure 4

Description

The present invention relates to an image recording device, an abnormality detection control method and a program.

There is an image recording device that operates a plurality of recording elements and performs a recording operation at a pixel position corresponding to each recording element on the medium. Some recording elements have nozzles and eject ink. In this image recording device, as the number of recording elements increases, the possibility that a part of the recording elements malfunctions increases.

In such an image recording device, a margin of a medium is used or a normal image recording operation is temporarily interrupted to record a detection image of an operation abnormality of each recording element and analyze the detected image. There is a technique to identify the presence or absence of abnormal operation. However, there is a problem that the size of the detected image increases as the number of recording elements increases and the resolution increases, which requires a larger space and takes time and effort. Patent Document 1 discloses a technique for detecting an abnormality by ejecting ink only from a nozzle used for recording an image to be recorded.

Further, in Patent Document 2, when the ejection abnormality of each nozzle is periodically detected, a list of defective nozzles is stored, and the recorded image has a defect more than a reference with respect to the original image data. , A technique for identifying a nozzle corresponding to the defect based on a list is disclosed.

Japanese Unexamined Patent Publication No. 2016-21014 Japanese Unexamined Patent Publication No. 2018-51846

However, there are various factors in the recording abnormality, not only the ejection failure from the nozzle, and there is a problem that it takes time and effort to record the detection image corresponding to each abnormality by brute force or the like to identify the abnormality. ..

An object of the present invention is to provide an image recording device, an abnormality detection control method, and a program capable of more easily identifying an abnormality.

In order to achieve the above object, the invention according to claim 1 is
A recording operation unit having a plurality of recording elements and recording an image on a medium by operating each of the plurality of recording elements.
Control unit and
With
The plurality of recording elements are grouped into a plurality of drive units, and the plurality of recording elements are grouped into a plurality of drive units.
The control unit sets the original image data to be recorded so that the recording element is not recorded for each drive unit, and the recording operation of a part of the set drive units is not performed by the recording element. It is an image recording device characterized by recording data.

Further, the invention according to claim 2 is the image recording apparatus according to claim 1.
The control unit is characterized in that the driving unit that does not perform the recording operation of the recording element is determined based on the content of the original image data.

Further, the invention according to claim 3 is the image recording apparatus according to claim 2.
The content of the original image data related to the operation setting of the drive unit is characterized in that at least a part of the colors, the recording range, and the printing rate used for recording the original image data is included.

Further, the invention according to claim 4 is the image recording apparatus according to claim 2 or 3.
The control unit
The arrangement pattern of the missing image is determined based on the contents, and
At the time of recording the missing image, the driving unit for not performing the recording operation on the recording element is determined according to the arrangement pattern.

The invention according to claim 5 is the image recording apparatus according to any one of claims 1 to 4.
The control unit
Acquire the setting of the type of the missing image to be recorded, and
The arrangement pattern of the missing image is determined based on the acquired setting, and the array pattern is determined.
At the time of recording the missing image, the driving unit that does not perform the recording operation of the recording element is determined according to the arrangement pattern.

The invention according to claim 6 is the image recording apparatus according to claim 5.
Equipped with an operation reception section
The control unit is characterized in that it acquires the setting of the type based on the input operation received by the operation reception unit.

Further, the invention according to claim 7 is the image recording apparatus according to claim 5 or 6.
The type includes a unit recording image in which a recording operation is performed by any one of the driving units with respect to the same position of the medium.

The invention according to claim 8 is the image recording apparatus according to any one of claims 1 to 7.
In the recording operation unit, the recording elements that perform recording operations in at least different colors belong to the drive units in which the recording elements are different from each other.
The control unit is characterized in that the drive unit that is not operated is determined for each color.

The invention according to claim 9 is the image recording apparatus according to any one of claims 1 to 8.
A transport unit for moving the medium in a predetermined direction is provided.
The recording operation unit is characterized by having a line head at each position of the medium in a width direction orthogonal to the predetermined direction so that the recording element performs a recording operation.

The invention according to claim 10 is the image recording apparatus according to any one of claims 4 to 7.
The arrangement pattern is characterized by including size information of the missing image.

The invention according to claim 11 is the image recording apparatus according to claim 10.
A transport unit for moving the medium in a predetermined direction is provided.
In the control unit, the total recording length of the missing image included in the array pattern in the predetermined direction is an integral multiple of the predetermined unit length of the image related to the original image data to be recorded in the predetermined direction. The recording length is determined as described above.

The invention according to claim 12 is the image recording apparatus according to claim 11.
The control unit is characterized in that the recording length of the missing image is set to be equal to or greater than the unit length of the image related to the original image data to be recorded in the predetermined direction.

The invention according to claim 13 is the image recording apparatus according to any one of claims 1 to 12.
When the control unit records the missing image in the middle of recording the normal image based on the original image data to be recorded a plurality of times, the control unit sets the start timing for recording the original image data of the missing image a plurality of times. It is characterized in that it is one of the start timings of recording.

The invention according to claim 14 is the image recording apparatus according to claim 13.
Equipped with an operation reception section
The control unit is characterized in that the recording operation of the missing image is started by the recording operation unit at the first start timing after the operation reception unit receives a predetermined input operation.

The invention according to claim 15 is the image recording apparatus according to claim 13 or 14.
A transport unit for moving the medium in a predetermined direction is provided.
The recording operation unit performs a recording operation for each ink landing position two-dimensionally determined by the recording element to record a halftone image.
The control unit causes the recording element to perform a recording operation in units of a plurality of lines according to the ink landing positions arranged in a width direction perpendicular to the predetermined direction, and is based on the number of the lines subjected to the recording operation. It is characterized in that the start timing is specified.

The invention according to claim 16 is the image recording apparatus according to claim 15.
A transport measuring unit for measuring the amount of transport by the transport unit is provided.
The control unit is characterized in that the number of lines is specified based on a predetermined transfer amount measured by the transfer measurement unit.

The invention according to claim 17 is the image recording apparatus according to any one of claims 1 to 16.
The control unit is characterized in that all the drive signals corresponding to the original image data are converted into signals that do not drive the recording operation and output to the drive unit that does not perform the recording operation.

The invention according to claim 18 is the image recording apparatus according to any one of claims 1 to 16.
The control unit is characterized in that it selectively outputs one of a drive signal corresponding to the original image data related to the drive unit and a drive signal that does not perform a recording operation.

The invention according to claim 19 is the image recording apparatus according to any one of claims 1 to 18.
The control unit sets a range of the drive unit for performing the recording operation of the missing image, and is characterized in that the recording operation by the drive unit not included in the range is not performed while the missing image is recorded. And.

The invention according to claim 20 is the image recording apparatus according to any one of claims 1 to 19.
An imaging unit for imaging the surface of the medium is provided.
The control unit is characterized in that the imaged data of the missing image by the imaging unit is compared with the original image data of the missing image, and an abnormality in the missing image is determined based on a predetermined criterion.

The invention according to claim 21 is the image recording apparatus according to claim 20.
The control unit estimates the cause of the abnormality based on the determined abnormality, and identifies the recommended operation according to the result of the estimation.

The invention according to claim 22 is the image recording apparatus according to claim 21.
Equipped with a display
The control unit is characterized in that the specified recommended operation is displayed by the display unit.

The invention according to claim 23 is the image recording apparatus according to claim 21 or 22.
Equipped with an operation reception section
The control unit
Based on the input operation received by the operation reception unit, the setting of the type of the missing image to be recorded is acquired.
The arrangement pattern of the missing image is determined based on the acquired setting, and the array pattern is determined.
At the time of recording the missing image, the driving unit that does not perform the recording operation of the recording element is determined according to the arrangement pattern.
It is characterized in that the reference is adjusted based on the determined information relating to the sequence pattern and the determined abnormality.

Further, the invention according to claim 24
It has a plurality of recording elements, includes a recording operation unit that records an image on a medium by operating each of the plurality of recording elements, and the plurality of recording elements are grouped into a plurality of drive units. This is a method for detecting and controlling abnormalities in an image recording device.
For the original image data to be recorded, a detection image is set for each drive unit so that the recording element is not recorded, and a missing image in which the recording element of some of the set drive units is not recorded is recorded. It is characterized by including a recording step.

Further, the invention according to claim 25
It has a plurality of recording elements, and includes a recording operation unit that records an image on a medium by operating each of the plurality of recording elements, and the plurality of recording elements are grouped into a plurality of drive units. The computer of the image recording device
For the original image data to be recorded, a detection image is set for each drive unit so that the recording element is not recorded, and a missing image in which the recording element of some of the set drive units is not recorded is recorded. It is a program characterized by functioning as a recording means.

According to the present invention, there is an effect that the abnormality can be identified more easily.

It is a front view explaining the outline of the whole structure of the inkjet recording apparatus. It is a bottom view which shows the surface which faces the transport surface in a head unit. It is a block diagram which shows the functional structure of an inkjet recording apparatus. It is a figure explaining the image output for abnormality detection. It is a figure which shows the example of the display screen which concerns on the image setting for abnormality detection. It is a flowchart which shows the control procedure of the image recording control processing. It is a flowchart which shows the control procedure of the abnormality detection image recording processing called in the image recording control processing. It is a flowchart which shows the control procedure of the image recording control processing of the modification 1. It is a flowchart which shows the control procedure of the abnormality detection image recording processing of the modification 2. It is a flowchart which shows the control procedure of the image recording control processing of the modification 2.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a front view illustrating an outline of the overall configuration of the inkjet recording device 100, which is the image recording device of the present embodiment.

The inkjet recording device 100 includes a medium feeding unit 10, a recording unit 20, a drying unit 30, a medium discharging unit 40, and the like.

The medium delivery section 10 includes a medium roll 11, a delivery roller 12, and the like. A continuous recording medium M (medium), such as roll paper or cloth, is wound around the medium roll 11. The medium roll 11 rotates at a speed corresponding to the transfer speed of the transfer unit 55 (see FIG. 3) to send the recording medium M to the transfer path of the transfer unit 55. The delivery roller 12 delivers the recording medium M to the transport unit 55 (recording unit 20) while stretching the recording medium M with an appropriate tension. The recording medium M is horizontally sent to the recording unit 20 with wrinkles and slacks stretched out.

The recording unit 20 includes a drive roller 21, a driven roller 22, a conveyor belt 23, an encoder 24 (conveyor measurement unit), a head unit 25 (recording operation unit), an imaging unit 26, and the like.

The drive roller 21 rotates in response to the operation of a drive motor (not shown), and orbits the transport belt 23 at a predetermined speed. The transport belt 23 is an endless (annular) belt member, and is bridged between the drive roller 21 and the driven roller 22. The transport belt 23 orbits according to the rotational operation of the drive roller 21. Along with this, the recording medium M placed on the transport surface in a predetermined range with the outer peripheral surface of the transport belt 23 as the transport surface is transported and moved in a predetermined direction (convey direction) along the transport path. The transport surface may be coated with an adhesive or the like so that the recording medium M can be adhered. Further, a holding roller (not shown) for adhering the recording medium M to the conveying surface may be provided. The driven roller 22 rotates according to the orbital movement of the transport belt 23.

The encoder 24 is a rotary encoder, and by detecting the rotation of the drive roller 21, the movement amount of the transfer belt 23, that is, the transfer amount is measured. The encoder 24 outputs a detection signal according to the rotation direction to the control unit 70 (see FIG. 3) for each rotation of a predetermined angle.

The head unit 25 has a recordable width (total width) of the recording medium M in a width direction perpendicular to (intersecting) the transport direction in the plane of the recording medium M mounted on the transport belt 23. Alternatively, it has a line head provided with a plurality of recording elements 25a (see FIG. 3) over a predetermined margin at both ends. Each of the recording elements 25a discharges ink to perform a band-shaped (linear) recording operation, and records an image (two-dimensional image) to be recorded on the recording medium M in combination with the transport operation. A plurality of head units 25, in this case eight head units 25, may be provided in order at different positions (predetermined positions) in the transport direction. These head units 25 may be set to eject inks of different colors, for example, in addition to inks of each color of C (cyan), M (magenta), Y (yellow), and K (black). Then, LC (light cyan) or S (sky), LM (light magenta) or P (pink), G (gray) and O (orange) are sequentially discharged from the upstream side in the transport direction. The color of the ink supplied to the head unit 25 may be replaceable or changeable.

The imaging unit 26 images the surface of the recording medium M on the downstream side of the head unit 25 in the transport direction. The image pickup unit 26 has, for example, a one-dimensional image pickup sensor. In the one-dimensional image pickup sensor, a plurality of image pickup elements are arranged here over the width of the transport belt 23 in at least the width direction. By moving the recording medium M in the transport direction, the imaging unit 26 can take a two-dimensional image on the recording medium M. Examples of the image pickup sensor include a CCD sensor (Charge Coupled Device) and a CMOS sensor (Complementary Metal Oxide Semiconductor). Each of these image pickup sensors performs an image pickup operation in which an electric charge amount and a voltage corresponding to the amount of light input to the light receiving element from the surface of the recording medium are output from the surface of the recording medium via an optical system (lens). Here, the image pickup sensor can take an image in each of the RGB wavelength bands (a plurality of wavelength bands), and the image pickup unit 26 can acquire a color-read image. The imaging unit 26 may include an illumination unit (not shown). The illumination unit irradiates the image pickup surface of the image pickup unit 26 substantially evenly. The imaging unit 26 may be positioned so as to perform imaging on the downstream side in the transport direction rather than the post-processing such as the drying unit 30.

The drying unit 30 dries and fixes the ink on the recording medium M on the downstream side of the head unit 25 (recording unit 20) in the transport direction. The drying unit 30 includes transport rollers 31 and 32, a drying operation unit 35, and the like.

The transport rollers 31 and 32 move the recording medium M sent out from the recording unit 20 in the drying unit 30. The transport rollers 32 are two transport rollers that hold the recording medium M after the ink has dried. The transport roller 32 generates a force to pull the recording medium M, and is placed on the transport belt 23. In particular, the adhesive recording medium M is peeled off from the transport belt 23 and pulled into the drying unit 30.

The drying operation unit 35 performs an operation for drying and fixing the ink on the recording medium M. Here, the drying operation unit 35 heats and / or blows air for evaporating the water content of the water-based ink. Although not particularly limited, the drying unit 30 has a housing, and the drying operation unit 35 is provided inside the housing and has a structure in which the heat generated by the drying operation unit 35 can be easily maintained. .. The internal air containing water vapor may be naturally discharged from the gap of the housing (including the air that is blown by the wind generated by the movement of the recording medium M or the transport belt 23), or may be forcibly discharged by an exhaust fan or the like. good.

The medium discharge unit 40 includes a discharge roller 41, and the ink is dried and fixed, and the recording medium M sent out from the drying unit 30 is shaken off to a tray or the like at the bottom (not shown). The discharged recording medium M may be appropriately sent to an aftertreatment device or the like for cutting or the like.

FIG. 2 is a bottom view showing a surface of the head unit 25 facing the transport surface.
Since all of the eight head units 25 have the same shape and configuration, any one of them will be described here.

Here, a plurality of, for example, eight recording heads 251 (drive units) are fixed to the head unit 25. On the bottom surface of each recording head 251, a plurality of nozzles N openings are arranged in the width direction at a predetermined nozzle pitch. The opening positions of the nozzles N may be different in the transport direction as long as they are arranged at predetermined intervals in the width direction. Although not particularly limited, in each of the recording heads 251 the openings of the nozzles N are located in a houndstooth pattern. The number and size of the openings of the nozzle N shown in this figure are for the purpose of explanation, and as will be described later, the number and the size are actually larger than this, and the size is the arrangement range of the nozzle N in the width direction. Small enough compared to the width of.

The eight recording heads 251 included in one head unit 25 are located on the bottom surface of the head unit 25 in a houndstooth pattern. Along with this, the arrangement ranges of the nozzle N in each recording head 251 in the width direction are located differently from each other, and image recording can be performed in different recording ranges according to these positions. The ends of the arrangement range in the width direction of the nozzles N in the adjacent recording heads 251 are slightly overlapped. Therefore, in the head unit 25, by combining the recording ranges in the width direction of the eight recording heads 251 with the above nozzle pitch over the entire width of the recording medium (there may be some margins at both ends) in the width direction. It has a line head structure capable of ejecting ink from a plurality of nozzles N divided into each recording head 251. Therefore, it is possible to perform an image recording operation in a single-pass system in which the recording medium M can be conveyed while the position of the head unit 25 is fixed and the ink can be landed on each position of the recording medium M with a single ink ejection. .. The ink of each color is ejected as minute droplets by the nozzle N of each head unit 25. Each of the fine droplets lands on the recording medium M and becomes fine dots. As a result, the recording medium M records a mixed color image expressed by the density and the combination thereof according to the number of fine dots, the size of the dots (the amount of droplets), and the like.

FIG. 3 is a block diagram showing a functional configuration of the inkjet recording apparatus 100.

In addition to the head unit 25 and the drying operation unit 35, the inkjet recording device 100 communicates with the transport unit 55, the detection unit 60, the control unit 70, the storage unit 80, the display unit 91, and the operation reception unit 92. A section 93, a bus 99, and the like are provided. The detection unit 60 includes the above-mentioned encoder 24, an imaging unit 26, and the like.

The head unit 25 includes a head drive unit 51 and the like in addition to the above-described configurations. The head drive unit 51 includes an electromechanical conversion element 511, a non-discharge setting unit 512, and the like. By deforming the electromechanical conversion element 511 according to the applied voltage, that is, the output voltage of the drive signal, the ink flow path, particularly the pressure chamber whose size and shape are determined to appropriately cause pressure fluctuation, is formed. Transform. The voltage waveform pattern of the drive signal is predetermined, and corresponds to the electromechanical conversion element 511 corresponding to each nozzle according to the control signal from the control unit 70 and the drive image data (halftone image data). Whether or not to output the drive signal in the voltage waveform pattern is determined. The ink extruded from the nozzle N by the deformation operation of the electromechanical conversion element 511 (recording operation of the recording element 25a) by the drive signal is separated from the ink in the ink flow path by an appropriate amount and discharged as ink droplets. .. The ink ejection amount (droplet amount) may be set in a plurality of stages, for example, three stages. The voltage waveform pattern corresponding to each set discharge amount is determined. The electromechanical conversion element 511 and the nozzle N are included in the recording element 25a. As described above, each recording element 25a belongs to one of the recording heads 251 (group) and is provided separately. That is, each recording element 25a belongs to a recording head 251 that is different for each color of the ink to be ejected, and each recording head 251 belongs to a head unit 25 that is different for each ink color.

The non-ejection setting unit 512 is set to uniformly prohibit ink ejection from all nozzles N of the designated recording head 251 regardless of a signal indicating the presence or absence of ink ejection from each nozzle N according to the image data to be recorded. I do. The non-discharge setting unit 512 will be described later.

The transport unit 55 moves the recording medium M in the above-mentioned transport direction (may change in the middle) along the transport path. The transport unit 55 includes a transport drive unit 551. The transport drive unit 551 operates each unit related to the transport operation of the recording medium M. The media roll 11 and the feeding roller 12 of the medium feeding unit 10, the driving roller 21 and the driven roller 22 of the recording unit 20, the transport rollers 31 and 32 of the drying unit 30, and the medium discharging unit 40 are discharged to each part related to the transport operation. The roller 41 and a rotary motor for rotating a part or all of them are included. The drive timing and drive speed of each rotary motor are synchronized, and a part thereof may be appropriately adjusted according to a situation such as tension applied to the recording medium M. The configuration related to the transport of the recording medium M is not limited to the one in which the endless belt is orbitably moved by a roller. For example, the recording medium M may be moved directly by the roller, or the recording medium M may be moved along the surface of a cylindrical rotating drum larger than the roller.

The control unit 70 is a hardware processor that controls the overall operation of the inkjet recording device 100. The control unit 70 includes a CPU 71 (Central Processing Unit), a RAM 72 (Random Access Memory), and the like. The control unit 70 performs various processes related to image recording based on image data, status signals of each unit, clock signals, and the like. Further, the control unit 70 performs operations such as operation adjustment related to ink ejection from each nozzle N, detection of a defective state of ejection operation and its corresponding processing, and detection and adjustment of image quality deterioration. The image data processing includes a process of converting the original image data to be recorded into halftone image data that defines the presence or absence of ink ejection operation in units of the electromechanical conversion element 511. The halftone image is data (line data) in units of lines indicating ink ejection / landing by each recording element 25a to each position (ink landing position) in the width direction with respect to a certain position in the transport direction. It is two-dimensional data in which a plurality of data are arranged for each position of. The distance between the lines in the recorded image is determined by the transport speed of the recording medium M and the ink ejection frequency.

The CPU 71 performs various arithmetic processes to control the transfer of the recording medium, the supply of ink, the ejection of ink, the reading operation of the recorded image, and the like in the inkjet recording apparatus 100. The CPU 71 performs calculations and controls related to each of the above processes according to a program read from the storage unit 80.

The RAM 72 provides the CPU 71 with a working memory space and stores temporary data. The storage area for temporary data may be appropriately shared with the DRAM area of the storage unit 80.

The control unit 70 includes an image recording control unit 75. The image recording control unit 75 controls the image recording operation in the head unit 25 based on the image data (original image data) to be recorded. The image recording control unit 75 may have a CPU and a RAM separately from the CPU 71 and the RAM 72, or the CPU 71 and the RAM 72 may be used in combination. When having a separate CPU and RAM, the image recording control unit 75 may be located in the head unit 25. Further, a part or all of the processing of the image recording control unit 75 may be performed by a hardware processor such as a dedicated logic circuit instead of the CPU. When the non-ejection pattern 751 which is the arrangement pattern of the non-ejection recording head 251 is determined, the image recording control unit 75 temporarily stores the non-ejection pattern 751.

The storage unit 80 stores the program 81, various setting data, job data 84 related to the image recording command, and the like. The job data 84 includes image data to be recorded, processed data thereof, information related to operation settings, and the like. The program 81 includes a program related to image recording processing, a program for detecting an image quality abnormality, a processing program for dealing with an image determined to be abnormal, and the like. As the setting data, the abnormality determination standard data 83 for identifying the image quality abnormality based on the ejection abnormality nozzle list 82 indicating the position of the nozzle causing the ink ejection abnormality and the imaging data by the imaging unit 26 (predetermined reference). Etc. are included.

The storage unit 80 includes a volatile memory such as a DRAM and a non-volatile memory here. Temporary data such as job data and processing data may be stored in the volatile memory for high-speed processing and may be deleted after the image recording operation is completed. Programs, setting data, and the like are held by the non-volatile memory, and are held even when the power is not supplied to the inkjet recording device 100. Some programs and setting data, such as initial data and core programs, may be stored in a non-volatile ROM or the like instead of the non-volatile memory.

The display unit 91 displays the status of the inkjet recording device 100, the operation menu, and the like on the display screen in response to the control signal from the control unit 70. Examples of the display screen include a liquid crystal screen. Further, the display unit 91 may include an LED lamp or the like that warns of the presence / absence of power supply and / or an error.

The operation reception unit 92 receives the user's operation and outputs it to the control unit 70. The operation reception unit 92 has, for example, a touch sensor or the like. The touch sensor may be provided so as to be superimposed on the display screen of the display unit 91 and used as a touch panel. The operation reception unit 92 outputs information on the position and type of touch operation detected by the touch sensor to the control unit 70. Further, the operation receiving unit 92 may have a push button switch and / or a numeric keypad.

The communication unit 93 is a communication interface that controls the communication operation with the external device. The communication interface includes, for example, one or a plurality of network cards corresponding to various communication protocols such as LAN cards. The communication unit 93 can acquire image data to be recorded and job data including settings related to image recording from an external device based on the control of the control unit 70, and can also transmit status information and the like to the external device. can.

The bus 99 is a path for electrically connecting the control unit 70 and each configuration that exchanges signals with the control unit 70, and transmitting the signal.
Of the above, at least the control unit 70 may be included in the computer of the present embodiment, and the storage unit 80, the display unit 91, the operation reception unit 92, the communication unit 93, the bus 99, and the like may be included in the computer.

Next, the operation of detecting an image quality abnormality in the inkjet recording apparatus 100 of the present embodiment will be described. The inkjet recording apparatus 100 detects an abnormality at the start of a job, periodically during the execution of a plurality of jobs, and / or at a timing corresponding to the reception of an operation input to the operation reception unit 92 by a user or the like. Record the image for judgment. Then, the user looks at the image for detecting an abnormality and confirms what kind of abnormality occurs in which position (range).

FIG. 4 is a diagram illustrating an image output for detecting an abnormality.
As shown in FIG. 4A, the images for abnormality detection and determination recorded at the start of the job are recorded at the same position by only one of the recording heads 251 and at the same position. It is a monochromatic image (unit recording image) in which an image to be recorded is separately recorded with each component of eight colors of ink so that the same image is recorded only in the same color. That is, based on the non-ejection pattern 751, a portion of the original image data to be recorded that corresponds to ink ejection from a recording head 251 of a color other than the recording head 251 belonging to the head unit 25 of a specific color is recorded. All 251 are set to non-ejection, and missing images (here, monochromatic images for each color) in which the recording operation is not performed by the recording element 25a of some of the recording heads 251 that are set to non-ejection are recorded, and the missing images are recorded. By checking the recording status, it is possible to easily identify what kind of abnormality has occurred in the ejection of which color of ink, and whether or not there is a deviation from the expected color tone even if it is not an abnormality. Here, as an example, monochromatic images are recorded in the order in which the head units 25 are arranged from the upstream side in the transport direction, that is, in the order of C, M, Y, K, LC, LM, G, O. It is not limited.

As the monochromatic image, each color component image of the image data to be recorded may be recorded as it is. That is, it is possible to transfer between the recording of a normal image and the recording of a monochromatic image based on the same image data without exchanging the original image data and the test image data. For example, a monochromatic image is recorded while the recording medium M is conveyed, and if there is no problem in the content of the recording, the operation shifts to a normal image recording operation without changing the set image data as it is. When the user can narrow down the problematic head unit 25, the recording head 251 and the cause of the problem by using the monochromatic image, the user performs an input operation instructing the operation reception unit 92 to perform processing according to the problem. By doing so, it shifts to an appropriate recovery process. Further, when recovery is difficult in the first place, for example, when the recording head 251 needs to be replaced, all the processes being executed may be stopped and the process may shift to a process of cutting off the power supply to each part.

Examples of the recovery process include a nozzle surface cleaning process for recovering ink ejection from an abnormal ejection nozzle and a forced ejection process by pressurizing the ink. Further, when it is necessary to replace the recording head 251 or the like, the image recording operation can be completely terminated and the power supply can be cut off.

On the other hand, when the cause cannot be narrowed down (for example, an abnormality that cannot be detected by the imaging result of the monochromatic image by the imaging unit 26 due to a malfunction of the transport unit 55 or the operation of the drying unit 30), When it becomes necessary to record a more accurate inspection image according to the narrowed down cause (for example, when the ejection failure nozzle cannot be identified with the accuracy of a single color image), the operation shifts to the recording operation of the inspection image. You may. Examples of the test image include a nozzle inspection chart for identifying an abnormal discharge nozzle, a streak inspection chart for specifying a position caused by a deviation in the discharge direction, and a color for specifying the amount of relative position deviation between the head units 25. A deviation inspection chart and the like can be mentioned. These test images need only be recorded by the recording head 251 of the head unit 25 in the vicinity of the abnormality.

Here, the monochromatic image is shown assuming that the entire image based on the original image data is recorded in all the colors of the inkjet recording apparatus 100, but it may be appropriately changed based on the content of the original image data. For example, in the case of repeating images of the same pattern, each monochromatic image may be longer than the size of the image of the same pattern as a unit length. In addition, each recording length is determined so that the total length (recording length) of each monochromatic image of multiple colors is an integral multiple of the unit length, so that the normal image can be quickly and without waste after the recording of the monochromatic image is completed. It is possible to shift to the image recording operation for detecting abnormalities of other types. In this case, the length of each unit image does not have to be an integral multiple of the unit length. Further, even if the images do not have the same pattern, the ink ejection from all the nozzles N used for the recorded image or the nozzles N set as the abnormality detection target may be appropriately covered. For example, when the recording range is limited (the margin is large), the monochromatic image of each color may be recorded only in the portion corresponding to the recording range. Further, a portion having a printing rate relatively lower than that of other portions may be excluded from the recording range of the monochromatic image. That is, the ink ejection from the recording head 251 that does not need to detect and determine the abnormality may not be performed at all during the recording operation of the image for detecting the abnormality. As described above, since the halftone image data is an arrangement of line data, the recording length and the unit length may be managed by the number of lines. The number of lines in which the recording operation is actually performed may be specified based on the number of encoder pulses output by the encoder 24 for each predetermined rotation angle (predetermined transfer amount).

As shown in FIG. 4B, when a monochromatic image is recorded in the middle of a plurality of normal image recording operations, the unit of the image currently being recorded ends, and normally the next normal image The timing at which the recording operation starts may be switched so as to be the timing at which the recording operation of the monochromatic image is started. For example, when a predetermined input operation related to a single color image recording request is received by the operation receiving unit 92 or the like at the position of the arrow, the normal recording operation is performed until the recording operation of the image being recorded at this point is completed. Is continued, and then, at the next (first) normal image recording start timing, the operation is switched to the abnormality detection image recording operation, and the monochromatic image recording operation is started. In this way, normal images during recording are not wasted in periodic abnormality detection and the like. Alternatively, the monochromatic image may be immediately switched to and the monochromatic image for exactly one cycle may be recorded. When a user or the like visually discovers an abnormality in the recorded image, the image currently being recorded also has an abnormality, and it is often not necessary to complete the image. Therefore, in this case, there is no problem even if the operation is promptly shifted to the single color image recording operation.

In FIG. 4C, as a missing image, seven two-color superimposed images of K (black) + another color are recorded following the monochromatic image. Since it is not possible to detect the positional deviation between colors in a monochromatic image, by outputting a superposed image with a reference color (here, K color, but not limited to this), eventually It is quickly known whether or not the recorded image of the color of is deviated from the reference position. It should be noted that the K-color head unit 25 may simply record a line indicating the reference position, for example, a straight line extending in the transport direction, without completely recording the image of the reference color. At this level, it is not necessary to replace the image data to be recorded with the data of another test image, and the control unit 70 may simply force the ink to be ejected from the specific nozzle N. Alternatively, a two-color superimposed image may be recorded with an arbitrary combination of selected colors, for example, all combinations of three colors having a high printing rate, without defining a reference color. In this case, if it is necessary to evaluate the amount of deviation quantitatively, it may be performed again using a test image or the like. The presence / absence of recording of the two-color superimposed image may be switched and set for each image recording operation for abnormality detection, or may be determined based on predetermined setting data or the like. Alternatively, depending on the abnormal situation, only the two-color superimposed image may be recorded and the monochromatic image may not be recorded. In these cases, before determining the non-discharge pattern 751, the setting for which type of abnormality detection image is to be recorded is acquired or set, and the non-discharge pattern 751 is set based on the setting. It should be generated. The type may be set based on, for example, an input operation received by the operation reception unit 92.

While the abnormality detection images such as these monochromatic images are being recorded, the transport speed of the recording medium M by the transport unit 55 may be lower than the transport speed during normal image recording operation. This enables users, administrators, and the like to check the recorded monochrome image in real time.

Further, when a user or an administrator notices an abnormality in real time during a normal recording operation, the position where the abnormality occurs in the width direction can be generally known. Therefore, in this case, it is not necessary to have all the recording heads 251 record the monochromatic image, and only a part of them may be selected. In addition, when it is determined that there is ink of an unused color based on the content of the original image data, or when the head unit 25 causing the abnormality can be narrowed down, the head unit 25 which is not the target is used. A non-ejection pattern 751 that defines a recording head 251 that is not ejected may be determined so as to omit the recording operation of the monochromatic image and the two-color superimposed image.

FIG. 5 is a diagram showing an example of a display screen related to image setting for abnormality detection.

The image setting screen for abnormality detection may be easily called by an operation reception unit 92, for example, one operation, particularly during a normal image recording operation. When the setting screen as shown in FIG. 5A is called and displayed, for example, the head unit 25 and the recording head 251 for recording a monochrome image are set as the output unit and the output head, respectively. It is possible. When the recording operation is performed by all the recording heads 251 of all the head units 25, "all" may be selected, or "all" may be set as the initial setting. By selecting and operating the output start button sign displayed on the display screen, the image setting for abnormality detection is started. The output unit and / or the output head may be narrowed down after the image setting for abnormality detection is started. In this case, for example, the operation of "setting change" is performed after the operation of "output start". Just do it. When the head unit 25 once excluded is reset, the monochromatic image recording operation of the reset head unit 25 may be performed by changing the order. Further, when the once excluded recording head 251 is reset, the recording operation of the monochromatic image by the head unit 25 in which the recording of the monochromatic image by the reset recording head 251 is omitted may be performed again. However, the recording head 251 may be operated only in the head unit 25 in which the recording operation is performed after the resetting.

Further, the combination of the output unit and the output head may be set by selecting and operating the "individual setting" button sign. When the "individual setting" is selected, as shown in FIG. 5B, the matrix display of the output unit and the output head may be displayed, and the presence or absence of the single color image recording operation may be individually set. For example, when the user notices the problem of image quality in two places at the same time, the recording head 251 based on the position in each width direction may be selected, and the head unit 25 corresponding to each color may be selected.

In this way, the output of the monochromatic image in units of the recording head 251, that is, the operation of uniformly prohibiting the ejection of ink from the recording heads 251 other than the recording head 251 that ejects a specific color related to the monochromatic image is the image recording control. It may be performed by the non-discharge setting unit 512 based on the control signal corresponding to the non-discharge pattern 751 of the unit 75. The specific operation by the non-ejection setting unit 512 is not particularly limited, but for example, a logical product of an ink ejection signal and a signal indicating whether or not ink ejection is possible may be output to each recording head 251. When the ink ejection is prohibited, a signal indicating whether or not the ink ejection is possible can be set to a low level (0, etc.), for example, the ink ejection is not possible. As a result, all the signals that determine the operation of each recording element 25a are converted to low level (0) and output, and the recording element 25a is non-discharged. The non-ejection referred to here does not have to be non-operational, and a voltage waveform having a minute amplitude that does not eject ink may be output and applied. Alternatively, the non-ejection setting unit 512 has a configuration in which either an ink ejection signal or a low-level signal that does not eject ink is selectively switched and output to each recording element 25a, for example, a switching element for recording that is not ejected. The switching element may be switched so that a low level signal is output to all the recording elements 25a of the head 251.

Alternatively, the image recording control unit 75 generates image data in which all the discharge operations from the recording head 251 that are non-discharged according to the non-discharge pattern 751 are changed to non-discharge, and the image data is output to the head drive unit 51. Then, each electromechanical conversion element 511 may be deformed as usual.

FIG. 6 is a flowchart showing a control procedure by the control unit 70 (which may include the image recording control unit 75) of the image recording control process executed by the inkjet recording device 100. This image recording control process including the abnormality detection control method of the present embodiment can detect an abnormality at the beginning of a job, and is started when a job related to an image recording command is input.

When the image recording control process is started, the control unit 70 (CPU71) acquires job data and generates drive image data for operating the head drive unit 51 to record the image to be recorded (step S101). ). The control unit 70 outputs a control signal to the transport unit 55 to start the transport operation of the recording medium (step S102).

The control unit 70 determines whether or not to record the abnormality detection image (step S103). The recording of the abnormality detection image may be regarded when a predetermined user operation is accepted, or conversely, it may be executed unless an abbreviated instruction is accepted by the predetermined user operation. Further, the setting data of whether or not to record may be separately held. If it is determined that recording is not performed (“NO” in step S103), the process of the control unit 70 shifts to step S106.

When it is determined that the abnormality detection image is to be recorded (“YES” in step S103), the control unit 70 calls and executes the abnormality detection image recording process (step S104). The control unit 70 determines whether or not the input corresponding to the recorded abnormality detection image has been made (step S105). If it is determined that no input has been made (“NO” in step S105), the process of the control unit 70 proceeds to step S106. If it is determined that the input has been made (“YES” in step S105), various processes according to the input contents are executed.

When the process shifts to the process of step S106, the control unit 70 shifts to the normal image recording operation (step S106). Even after shifting to the process of step S106, the recording of the abnormality detection image and the input operation corresponding to the determination result may be performed, and in response to the input operation, the process branches to "YES" in step S105. Each process may be executed. When the normal image recording operation is completed, the control unit 70 outputs a control signal to the transport unit 55 to stop the transport operation (step S107). Then, the control unit 70 ends the image recording control process.

FIG. 7 is a flowchart showing a control procedure by the control unit 70 of the abnormality detection image recording process called in the image recording control process.
When the abnormality detection image recording process is called, the control unit 70 (CPU71) acquires information on the recording head 251 to be detected (may be all the recording heads 251 belonging to a certain head unit 25) (step S201). .. This information is acquired according to the content set on the above-mentioned setting screen.

The control unit 70 determines a setting pattern (non-discharge pattern 751) of the head unit 25 and the recording head 251 that are sequentially non-discharged (step S202). In the non-ejection pattern 751, for example, the timing at which the recording operation of the recording element 25a of any of the recording heads 251 is first non-ejected, and the missing image data (information on the size of the missing image, particularly the length in the transport direction) are displayed. Information on the number of repetitions (including), the number of repetitions, and the switching order (including information on the type of missing image) of the recording head 251 that is not ejected is set. The control unit 70 calculates the recording start position (step S203). As described above, the control unit 70 may lower the transport speed at the time of recording the abnormality detection image more than usual, and in this case, based on the information of the speed change pattern during the speed reduction. The transport distance of the recording medium may be calculated. When the abnormality detection image recording process is called during the normal image recording operation in the image recording control process as described later, the information about the end position of the image currently being recorded is calculated in the calculation of the recording start position. , Or indirectly, information on the size of the normal image and the recording start position of the image currently being recorded may be included.

The control unit 70 identifies the current position of the recording medium based on the output of the encoder 24, and determines whether or not it is the recording start position (step S204). If it is determined that the recording start position is not reached (“NO” in step S204), the control unit 70 repeats the process of step S204.

If it is determined to be the recording start position (“YES” in step S204), the control unit 70 outputs a control signal to the head drive unit 51 to record an image for abnormality detection (monochromatic image, etc.). The operation is started (step S205; detection image recording step, detection image recording means). When the image recording operation for abnormality detection is completed, the control unit 70 ends the abnormality detection image recording process and returns the process to the image recording control process. As described above, the information of the recording head 251 to be detected may be changed in the middle before the image recording operation for abnormality detection is completed. The control unit 70 updates the non-ejection pattern 751 according to the changed setting, and determines a period during which each recording head 251 is not ejected ink according to the non-ejection pattern 751.

[Modification 1]
FIG. 8 is a flowchart showing a control procedure by the control unit 70 of the image recording control process of the first modification. In the image recording control process of the first modification, as shown in FIGS. 4 (b) and 4 (c), the abnormality detection image is recorded by interrupting not only before the start of recording the normal image but also during the recording operation of the normal image. It can be performed. Correspondingly, the processes of steps S111 to S117 are added to the image recording control process of the first modification. Further, instead of the process of step S107, the process of step S121 is added. The other processes of steps S101 to S106 are the same as the image recording control process in the above embodiment, and the same reference numerals are given and the description thereof will be omitted.

When the process shifts to the normal image recording operation in step S106, the control unit 70 determines whether or not all the image recording operations specified by the job have been completed (step S111). If it is determined that the process has been completed (“YES” in step S111), the control unit 70 outputs a control signal to the transfer unit 55 to stop the transfer operation (step S121). Then, the control unit 70 ends the image recording control process.

If it is determined that the recording operation has not been completed (“NO” in step S111), the control unit 70 determines whether or not the image output command for abnormality detection has been acquired (step S112). If it is determined by the operation receiving unit 92 or the like that the image output command for abnormality detection has not been acquired (“NO” in step S112), the processing of the control unit 70 returns to step S111.

When it is determined that the image output command for abnormality detection has been acquired (“YES” in step S112), the control unit 70 calls and executes the abnormality detection image recording process shown in FIG. 7 (step S113). .. The control unit 70 outputs a control signal to the transport unit 55, records the abnormality detection image, and then suspends the transport operation (step S114).

The control unit 70 acquires the content of the corresponding operation input by the operation reception unit 92 or the like based on the recorded abnormality detection image (step S115). The control unit 70 determines whether or not a corresponding operation is required according to the acquired content (step S116). If it is determined that no action is required (“NO” in step S116), the control unit 70 restarts the transport operation and the recording operation (step S117), and returns the process to step S111. When it is determined that the processing is necessary (“YES” in step S116), the control unit 70 shifts to the necessary corresponding processing.

The abnormality detection image recording process executed during the normal image recording operation is performed not only when a command is received by the operation reception unit 92, but also at a predetermined recording length of the normal image and at a predetermined time interval. , May be started automatically periodically. At this time, not only when there is a manual input to the operation reception unit 92, but also when there is no manual input, it may be retained as history data in association with the automatic determination result.

[Modification 2]
In the above embodiment and the first modification, the user detects the abnormality and estimates the cause based on the abnormality detection image, but these processes are completely or supplementarily based on the abnormality determination criterion data 83. It may be performed by the control unit 70. The abnormality detection image is captured by the imaging unit 26, and the captured data is compared with the original image data. In the image recording operation, it is only necessary to obtain the image quality required for the recorded image, so that it is not necessary to detect a minute abnormality exceeding the required level. Therefore, the abnormality detection standard according to the required level may be set in advance as the abnormality determination standard data 83 and compared with the magnitude of various abnormalities in the imaging data. Examples of the magnitude of the abnormality to be compared include the magnitude of the density unevenness, the difference in the density unevenness of the images of each color, and the magnitude of the deviation between the images of each color.

The abnormality determination standard data 83 may be set according to a plurality of levels, or may be a single level. Moreover, these determination criteria may be variable.

FIG. 9 is a flowchart showing a control procedure of the abnormality detection image recording process when the abnormality detection is automatically performed. In this abnormality detection image recording process, the processes of steps S206 to S208 are added to the abnormality detection image recording process of the above embodiment shown in FIG. 7. The other processes of steps S201 to S205 are the same as each other and are designated by the same reference numerals, and the description thereof will be omitted.

When the image recording operation for abnormality detection is started in the process of step S205, the control unit 70 captures the recorded image for abnormality detection by the imaging unit 26 and acquires the imaging data (step S206). The control unit 70 compares the captured data with the original image data for recording the image for abnormality detection, and is there a portion recognized as an abnormality in the image for abnormality detection based on the abnormality determination reference data 83? The control unit 70 estimates the cause of the abnormality and identifies the recommended operation for the occurrence of the abnormality of the estimated factor (step S207). The correspondence relationship between the abnormal factor and the recommended operation may be stored in advance in association with the storage unit 80. The control unit 70 outputs information on the detection location of the abnormality, the cause of the estimated abnormality, the content of the recommended operation (for example, a specific operation procedure), and the like (step S208). For example, the control unit 70 causes the display unit 91 to display the detection location of these abnormalities, the cause of the abnormality, the content of the recommended operation, and the like. Then, the control unit 70 ends the abnormality detection image recording process and returns the process to the image recording control process.

FIG. 10 is a flowchart showing a control procedure of the image recording control process for calling the abnormality detection image recording process of the second modification. In this image recording control process, the process of step S105 is deleted and the processes of steps S131 to S138 are added to the image recording control process of the first modification. The other processes are the same between the modified examples 1 and 2, and the same processes are designated by the same reference numerals and the description thereof will be omitted.

Following the processing in step S104, whether or not the control unit 70 is set to automatically perform the corresponding processing as necessary based on the abnormality location identified by the abnormality detection image recording processing and the estimated cause of the abnormality. (Step S131). When it is determined that the setting to automatically perform the correspondence process is made (“YES” in step S131), the control unit 70 determines whether or not some correspondence is required (step S132). When it is determined that the response is required (“YES” in step S132), the control unit 70 shifts to the response process set as required. If it is determined that it is not required (“NO” in step S132), the process of the control unit 70 shifts to step S106.

If it is determined that the setting for automatic correspondence has not been made (“NO” in step S131), the control unit 70 acquires the input content of the correspondence received by the operation reception unit 92 or the like (step S133). ). The control unit 70 compares the automatic correspondence setting result (recommended operation) with the input correspondence content (determined non-discharge pattern 751), and reflects and adjusts it in the standard of automatic abnormality detection ( Step S134). The control unit 70 determines whether or not the input content requires some kind of corresponding processing (step S135). If it is determined that the request is made (“YES” in step S135), the process proceeds to the requested corresponding process. If it is determined that none of the corresponding processes is required (“NO” in step S135), the process of the control unit 70 proceeds to step S106.

After the abnormality detection image recording process of step S113 is executed, the control unit 70 automatically responds as necessary based on the abnormality location identified by the abnormality detection image recording process and the estimated cause of the abnormality. It is determined whether or not the setting is made (step S136). When it is determined that the setting to automatically perform the correspondence process is made (“YES” in step S136), the control unit 70 determines whether or not some correspondence is required (step S137). When it is determined that the response is required (“YES” in step S137), the control unit 70 shifts to the response process set as required. If it is determined that it is not required (“NO” in step S137), the process of the control unit 70 returns to step S111.

If it is determined that the setting for automatic correspondence has not been made (“NO” in step S136), the processing of the control unit 70 proceeds to step S114. After the processes of steps S114 and S115 are performed, the control unit 70 compares the automatic correspondence setting result with the input correspondence content and reflects it in the standard of automatic abnormality detection (step S138). Then, the process of the control unit 70 shifts to step S116.

As described above, the inkjet recording apparatus 100 of the present embodiment has a plurality of recording elements 25a, and the head unit 25 that records an image on the recording medium M by operating each of the plurality of recording elements 25a for recording. And a control unit 70. The plurality of recording elements 25a are grouped into a plurality of recording heads 251. The control unit 70 sets the original image data to be recorded by setting the recording elements 25a not to be recorded for each recording head 251. A missing image (monochromatic image, etc.) that is not recorded by the recording element 25a of a part of the recording head 251 is recorded.
In this way, by recording the missing image obtained by decomposing the original image data in color units without changing the original image data, it is easy to identify where and what cause the image quality abnormality. Become. As a result, it is possible to quickly identify an appropriate one among various test images and corresponding processes, so that it is possible to reduce the time and effort for image quality abnormalities. Further, since the abnormality is detected based on the actual original image data, it is possible to detect an abnormality at a level depending on whether or not the image quality required by the user is satisfied, and conversely, the required image quality is satisfied. The trouble can be reduced by leaving the abnormality unattended. Further, since the abnormality can be easily determined by the recording target image data itself, the original image data recorded by the head drive unit 51 can be discarded once and the test image for abnormality detection can be read, or the original image data can be read again after the corresponding processing. The need to read the image is suppressed, and production can be performed more efficiently and quickly.

Further, the control unit 70 defines a recording head 251 that does not perform the recording operation of the recording element 25a based on the content of the original image data. Since it is sufficient that the accuracy of the image quality recorded according to the original image data can be obtained, it is not necessary to record the image for abnormality detection in the recording head 251 which has no relation or influence on the image quality. In this way, since the missing image to be recorded reflecting the content of the original image data is determined, the abnormality detection can be made more efficient.

Further, the content of the original image data related to the operation setting of the recording head 251 includes at least a part of the colors, the recording range, and the print rate used for recording the original image data. By determining the necessity of abnormality detection of each recording head 251 based on these and recording an image for abnormality detection in a necessary range, the detection work can be further made more efficient.

Further, the control unit 70 determines an arrangement pattern of the missing image (monochromatic image, etc.) based on the content of the original image data, and performs a recording operation on the recording element 25a according to the arrangement pattern at the time of recording the missing image. A recording head 251 that is not allowed to be set is defined. The non-ejection operation of the recording head 251 can be defined as a non-ejection pattern 751 based on the content of the original image data, and the non-ejection pattern 751 can be defined so that the recording heads 251 are not collectively ejected ink.
Therefore, in the inkjet recording apparatus 100, it is possible to easily determine whether or not the image recording operation is possible for each recording head 251 so that an image for abnormality detection can be recorded so that an abnormality can be easily and appropriately detected.

Further, the control unit 70 acquires the setting of the type of missing image to be recorded (single color image, two-color superimposed image, ink color for recording these, etc.), and based on the acquired setting, sets the arrangement pattern of the missing image. At the time of recording the missing image, the recording head 251 that does not perform the recording operation by the recording element 25a is defined according to the non-ejection pattern 751. The recording of the missing image may be performed based on the initial settings or the like, or may be limited to those that the user deems necessary according to the input operation of the user or the like. By flexibly acquiring and recording the necessary image recording range and contents for abnormality detection in this way, unnecessary image recording is not performed, unnecessary processing is not performed on the inkjet recording device 100, and the user is also extra. You don't have to spend a lot of time and effort.

In addition, the inkjet recording device 100 includes an operation reception unit 92. The control unit 70 acquires the setting of the type of the missing image to be recorded based on the input operation received by the operation reception unit 92. Since the type of the missing image can be determined each time based on the user operation, it is possible to flexibly obtain the necessary missing image according to the detection status of the abnormality by the user.

Further, this type includes a monochromatic image in which a recording operation is performed by any one of the recording heads 251 with respect to the same position of the recording medium M. By dividing the image at the same position without overlapping the inks from the plurality of nozzles N, it is possible to easily and more reliably determine which recording head 251 has an abnormality from the initial stage, which is appropriate and appropriate. Abnormalities can be dealt with promptly.

Further, in the head unit 25, recording elements 25a that perform recording operations in at least different colors belong to recording heads 251 that are different from each other, and the control unit 70 defines a recording head 251 that is not operated for each color and records a monochrome image. .. The monochromatic image makes it easier to determine which recording head 251 has an abnormality, and it is also possible to easily determine the user's subjective abnormality in the image with a small blur. ..

In addition, the inkjet recording device 100 includes a transport unit 55 that moves the recording medium M in the transport direction. The head unit 25 has a line head located at each position in the width direction orthogonal to the transport direction of the recording medium M so that the recording element 25a performs a recording operation. In the inkjet recording apparatus 100 using such a line head, an abnormality in image quality is likely to occur in response to an abnormality in units of nozzle N, so that this abnormality can be easily and appropriately determined. Further, such an inkjet recording device 100 often records a large number of the same images continuously at high speed for industrial use, and first records the above-mentioned abnormality detection image to quickly determine the abnormality. This makes it possible to reduce the time during which the image recording operation is stopped.

Further, the non-ejection pattern 751 includes size information of the missing image. Since the missing image does not have to be the entire image related to the original image data, the recording head 251 is appropriately set to non-eject so that the size information is set and the image for abnormality detection corresponding to a part is recorded. Can be set and switched.

Further, in the control unit 70, the total recording length of the missing image included in the non-ejection pattern 751 in the transport direction is an integral multiple of the predetermined unit length in the transport direction of the image related to the original image data to be recorded. Set the record length so that In an image recorded for industrial use, the same pattern may be output continuously and repeatedly without gaps, but the recording length is set so that the end position of the pattern is reached when all the missing images have been recorded. By defining the above, it is possible to quickly shift to the recording operation of another image such as a normal image without requiring unnecessary processing after the missing image is completed.

Further, the control unit 70 sets the recording length of the missing image to be equal to or greater than the unit length in the transport direction of the image related to the original image data to be recorded. That is, even if the boundary of the output image recording medium is not so important, by recording the image for abnormality detection with a length equal to or longer than the unit length of the recorded image, it is possible to suppress oversight of abnormalities that may occur in the image. be able to.

Further, when the control unit 70 records the missing image in the middle of recording the normal image based on the original image data to be recorded a plurality of times, the control unit 70 starts recording the missing image a plurality of times at the start timing of recording the original image data. Either of the timings. For example, in the case of periodically recording an image for abnormality detection, it is possible to appropriately sandwich the image without interrupting the recording of the normal image in the middle and wasting it.

Further, the control unit 70 starts the recording operation of the missing image by the head unit 25 at the first start timing after the operation reception unit 92 receives a predetermined input operation. That is, similarly to the above, even if the image recording command for abnormality detection is acquired in real time during the image recording operation, until the timing when the recording operation of the image being recorded ends and the next recording operation is started. By holding and switching to recording an image for abnormality detection, the image in the middle of recording is not wasted.

Further, the head unit 25 performs a recording operation with respect to the ink landing positions determined in a two-dimensional matrix by the recording element 25a to record a halftone image, and the control unit 70 is a line based on a plurality of ink landing positions arranged in the width direction. Is performed by the recording element 25a as a unit, and the recording start timing of the image for abnormality detection is specified based on the number of lines on which the recording operation is performed. Since the size of the recorded image, that is, the timing of switching to the recording operation of the next missing image can be easily specified only by detecting such a number of times, the switching operation of the recording head 251 defined as non-ejection can be easily and surely performed. Can be done.

In addition, the inkjet recording device 100 includes an encoder 24 that measures the amount of transportation by the transport unit. The control unit 70 specifies the number of lines based on the predetermined transfer amount measured by the encoder 24, that is, the number of output encoder pulses. Since the ink ejection operation is performed in synchronization with the encoder pulse, it is possible to easily and surely perform the switching operation of the recording head 251 defined as non-ejection by directly counting the encoder pulse.

Further, the control unit 70 may convert all the drive signals corresponding to the original image data into signals that do not drive the recording operation and output the recording head 251 that does not perform the recording operation. That is, since the original image data is collectively converted into a non-ejection signal before being output to each electromechanical conversion element 511 without being tampered with, there is no need to adjust the original image data.

Alternatively, the control unit 70 may selectively output either a drive signal corresponding to the original image data originally output to the recording head 251 or a drive signal that does not perform the recording operation. Even in this case, the original image data itself can be switched to a non-ejection signal without any changes, so it is necessary to adjust the original image data and hold the adjusted data in parallel, as well as memory space. do not.

Further, the control unit 70 sets a range of the recording head 251 for performing the recording operation of the missing image, and does not perform the recording operation by the recording head 251 not included in this range while recording the missing image. Since the recording head 251 that does not record the missing image is the recording head 251 that does not need to detect the abnormality, the image recording operation is consistently stopped while the image for detecting the abnormality is recorded. Therefore, unnecessary ink ejection can be suppressed, and unnecessary abnormality detection image recording operation can be omitted to reduce labor, cost, and time.

In addition, the inkjet recording device 100 includes an imaging unit 26 that images the surface of the recording medium M. The control unit 70 compares the imaged data of the missing image by the imaging unit 26 with the original image data of the missing image, and determines the abnormality in the missing image based on the abnormality determination reference data 83.
As described above, the abnormality determination may be performed not only visually by the user but also automatically by the control unit 70. Since it is a heavy burden for the user to constantly monitor while recording a large number of images, it is possible to reduce the time and effort of the user by enabling the automatic determination process. In addition, by making it possible to compare the judgment result with the judgment of the user, it is possible to give auxiliary information to the user and support the judgment of the user.

Further, the control unit 70 estimates the cause of the abnormality based on the determined abnormality, and identifies the recommended operation according to the estimation result. By not only determining the abnormality but also estimating the cause of the abnormality and specifying the action to be taken as a result, it is possible to reduce the burden and labor of a particularly unskilled user.

In addition, the inkjet recording device 100 includes a display unit 91. The control unit 70 causes the display unit 91 to display the specified recommended operation. As a result, it is possible to easily know and execute the operation content according to the action that the user should actually take. Moreover, even when the recommended operation is automatically executed, the user can know the content of the operation being executed.

Further, the control unit 70 determines the abnormality based on the information related to the determined non-discharge pattern, that is, various information acquired for determining the non-discharge pattern and the abnormality determined by the control unit 70. To adjust.
That is, when the control unit 70 detects and determines an abnormality, and when the user finally selects (does not) the image recording operation for detecting the abnormality, the difference is determined as the abnormality determination reference data 83. It can be reflected in the learning so as to reduce the deviation from the user's selection. This makes it possible to reduce the possibility of making a meaningless judgment far from the user's action and output a judgment result that is more useful to the user.

Further, in the abnormality detection control method of the inkjet recording apparatus 100, the recording element 25a is set not to be recorded for each recording head 251 with respect to the original image data to be recorded, and the recording element of some of the set recording heads 251 is set. The detection image recording step of recording a missing image in which the recording operation by 25a is not performed is included.
By performing such processing, it is possible to detect and discriminate various abnormalities and estimate the factors widely by using the original image data as it is. Therefore, it is possible to promptly take appropriate measures. If there is no abnormality, the normal image recording operation based on the original image data can be started / restarted as it is. Further, since the influence of the deterioration of the image quality on the original image data itself can be directly judged, it is possible to more accurately judge whether or not the abnormality is a minute abnormality and does not affect the required level of the normal image.

Further, by installing the program 81 that performs the above processing on the computer of the inkjet recording apparatus 100 and executing it as software by the CPU, a missing image in which the recording head 251 that is not ejected is easily switched is recorded, and an abnormality is obtained. Can be detected, the approximate location can be identified, the factors can be estimated, and the measures to be taken can be determined.

The present invention is not limited to the above embodiment, and various modifications can be made.
For example, in the above-described embodiment, a monochromatic image and a two-color superimposed image have been described as examples of missing images, but the present invention is not limited thereto. For example, when monochromatic parts exist at a plurality of places in an image such as a character image, these may be included in a single missing image. Further, images recorded by three or more head units 25 may be superimposed according to the type of abnormality to be identified.

Further, the two-color superimposed image does not have to be included in the missing image recorded first. Initially, only a monochromatic image is recorded, and based on this result, it may be treated as a part of a test image in which a recording operation command is further given.

Further, in the above embodiment, a missing image having a unit length or more of the original image data is recorded, but the unit length or more is not necessarily required depending on the content of the original image data, such as when the image is close to a solid image. It does not have to be. Further, it is not necessary to synchronize with the delimiter of the normal image recording, and the recording operation may be started after the image recording command for abnormality detection is acquired and the setting such as the type information is confirmed.

Further, the setting of the type of the image for abnormality detection is not limited to the case where the operation receiving unit 92 accepts the image. Setting information may be acquired from an external terminal device or the like via the communication unit 93.

Further, the switching timing of the non-ejection recording head 251 does not have to be determined according to the number of encoder pulses output by the encoder 24. Other methods, for example, the content of the output image data line itself may be used for determining the timing, or the elapsed time may be simply counted and switching may be performed.

Further, in the above embodiment, it has been described that the ink non-ejection setting can be performed collectively with the recording head 251 as a drive unit, but the present invention is not limited to this. When the head unit 25 has a single recording head 251, the ink non-ejection setting may be substantially made with the head unit 25 as a drive unit, or the recording elements 25a may be grouped into a plurality of groups in the recording head 251. It may be divided so that the ink non-ejection setting can be made with the group as the drive unit.

Further, in the above modification 2, it has been described that whether or not the above automatic detection determination is performed by the control unit 70 is set in advance, but even if the setting gives priority to the processing according to the user operation. It may be possible to switch to the execution of the recommended operation when there is no input for a predetermined time, or to perform a shortcut operation for the user to issue an operation command according to the recommended operation.

Further, in the above embodiment, the inkjet recording apparatus 100 having a line head has been described as an example, but the present invention is not limited to this. It may be a scan-type inkjet recording apparatus that records an image while scanning the recording head 251 (head unit 25) with respect to the recording medium M. Further, in the scan type inkjet recording apparatus that records an image in a multi-pass format, the same processing as that of the above-described embodiment can be performed by recording a missing image in which each drive unit is further separated in each pass.

Further, in the above embodiment, the image is recorded on the continuous recording medium M, but the same processing may be performed even when recording on an individual recording medium such as a sheet of paper. .. In this case, the size of the image for abnormality detection may be determined according to the size of the individual recording medium and the like.

Further, in the above embodiment, the processing operation for the abnormality of the image quality has been described, but the same processing may be performed when the image quality is different from the intended one although it cannot be said to be abnormal. In this case, the image for detecting anomalies is used to identify the cause of the image quality deviation. Therefore, the abnormality determination standard data 83 may include not only the abnormality standard but also the reference data for adjusting the color tone and the shade, for example. Then, based on this reference data, for example, the amount of deviation from the reference in the monochromatic image may be quantitatively evaluated.

Further, in the above embodiment, the inkjet recording device 100 has been described as an example of the image recording device, but if the image recording device has a plurality of recording elements and records an image by the operation of the recording elements, the inkjet recording is performed. It does not have to be a device. Further, the image recording operation referred to here is not limited to recording a flat image using a coloring material. It may contain transparent (light-transparent) ink or the like, or may be used for three-dimensional recording. Further, the image referred to here may have a function as a picture or a character, an image having no distinctiveness, for example, a single color plane (including transparency), and on the other hand, a function other than the picture or the character. For example, it may have a function as a protective film or electrical wiring.

Further, in the above description, the storage unit 80 having an auxiliary storage device such as a non-volatile memory and / or an HDD as a computer-readable medium of the program 81 related to the processing operation of the control unit 70 according to the present invention will be cited as an example. As explained, but not limited to this. As another computer-readable medium, a portable storage medium such as a CD-ROM or a DVD disc can be applied. A carrier wave is also applied to the present invention as a medium for providing data of a program according to the present invention via a communication line.
In addition, the specific configuration, the content and procedure of the processing operation, etc. shown in the above-described embodiment can be appropriately changed without departing from the spirit of the present invention. The scope of the present invention includes the scope of the invention described in the claims and the equivalent scope thereof.

10 Media delivery unit 11 Media roll 12 Feed roller 20 Recording unit 21 Drive roller 22 Driven roller 23 Conveyance belt 24 Encoder 25 Head unit 251 Recording head 25a Recording element 26 Imaging unit 30 Drying unit 31, 32 Conveying roller 35 Drying operation unit 40 Media Discharge unit 41 Discharge roller 51 Head drive unit 511 Electromechanical conversion element 512 Non-discharge setting unit 55 Conveyance unit 551 Conveyance drive unit 60 Detection unit 70 Control unit 71 CPU
72 RAM
75 Image recording control unit 751 Non-ejection pattern 80 Storage unit 81 Program 82 Discharge abnormality nozzle list 83 Abnormality judgment standard data 84 Job data 91 Display unit 92 Operation reception unit 93 Communication unit 99 Bus 100 Inkjet recording device M Recording medium N nozzle

Claims (25)

A recording operation unit having a plurality of recording elements and recording an image on a medium by operating each of the plurality of recording elements.
Control unit and
With
The plurality of recording elements are grouped into a plurality of drive units, and the plurality of recording elements are grouped into a plurality of drive units.
The control unit sets the original image data to be recorded so that the recording element is not recorded for each drive unit, and the recording operation of a part of the set drive units is not performed by the recording element. An image recording device characterized by recording data. The image recording device according to claim 1, wherein the control unit determines the drive unit that does not perform the recording operation of the recording element based on the content of the original image data. A claim that the content of the original image data related to the operation setting of the drive unit includes at least a part of a color, a recording range, and a print rate used for recording the original image data. 2. The image recording device according to 2. The control unit
The arrangement pattern of the missing image is determined based on the contents, and
The image recording apparatus according to claim 2 or 3, wherein when the missing image is recorded, the driving unit that prevents the recording element from performing the recording operation is determined according to the array pattern. The control unit
Acquire the setting of the type of the missing image to be recorded, and
The arrangement pattern of the missing image is determined based on the acquired setting, and the array pattern is determined.
The image recording apparatus according to any one of claims 1 to 4, wherein when the missing image is recorded, the driving unit that does not perform the recording operation of the recording element is determined according to the arrangement pattern. .. Equipped with an operation reception section
The image recording device according to claim 5, wherein the control unit acquires a setting of the type based on an input operation received by the operation reception unit. The image recording apparatus according to claim 5 or 6, wherein the type includes a unit recording image in which a recording operation is performed by any one of the driving units with respect to the same position of the medium. In the recording operation unit, the recording elements that perform recording operations in at least different colors belong to the drive units in which the recording elements are different from each other.
The image recording device according to any one of claims 1 to 7, wherein the control unit determines the drive unit that is not operated for each color. A transport unit for moving the medium in a predetermined direction is provided.
The recording operation unit has a line head located at each position in a width direction orthogonal to the predetermined direction of the medium so that the recording element performs a recording operation, respectively. The image recording device according to any one of the following items. The image recording apparatus according to any one of claims 4 to 7, wherein the array pattern includes size information of the missing image. A transport unit for moving the medium in a predetermined direction is provided.
In the control unit, the total recording length of the missing image included in the array pattern in the predetermined direction is an integral multiple of the predetermined unit length of the image related to the original image data to be recorded in the predetermined direction. The image recording apparatus according to claim 10, wherein the recording length is determined as described above. The image recording device according to claim 11, wherein the control unit determines the recording length of the missing image to be equal to or greater than the unit length of the image related to the original image data to be recorded in the predetermined direction. When the control unit records the missing image in the middle of recording the normal image based on the original image data to be recorded a plurality of times, the control unit sets the start timing for recording the original image data of the missing image a plurality of times. The image recording apparatus according to any one of claims 1 to 12, wherein the recording start timing is set to any one of them. Equipped with an operation reception section
The image recording according to claim 13, wherein the control unit starts a recording operation of the missing image by the recording operation unit at the first start timing after the operation reception unit receives a predetermined input operation. Device. A transport unit for moving the medium in a predetermined direction is provided.
The recording operation unit performs a recording operation for each ink landing position two-dimensionally determined by the recording element to record a halftone image.
The control unit causes the recording element to perform a recording operation in units of a plurality of lines according to the ink landing positions arranged in a width direction perpendicular to the predetermined direction, and is based on the number of the lines subjected to the recording operation. The image recording apparatus according to claim 13 or 14, wherein the start timing is specified. A transport measuring unit for measuring the amount of transport by the transport unit is provided.
The image recording device according to claim 15, wherein the control unit specifies the number of lines based on a predetermined transfer amount measured by the transfer measurement unit. The control unit is characterized in that, for the drive unit that does not perform the recording operation, all the drive signals corresponding to the original image data are converted into signals that do not drive the recording operation and output. The image recording apparatus according to any one of 16 to 16. The control unit according to claim 1 to 16, wherein the control unit selectively outputs one of a drive signal corresponding to the original image data related to the drive unit and a drive signal that does not perform a recording operation. The image recording apparatus according to any one item. The control unit sets a range of the drive unit for performing the recording operation of the missing image, and is characterized in that the recording operation by the drive unit not included in the range is not performed while the missing image is recorded. The image recording apparatus according to any one of claims 1 to 18. An imaging unit for imaging the surface of the medium is provided.
The claim is characterized in that the control unit compares the imaged data of the missing image by the imaging unit with the original image data of the missing image, and determines an abnormality in the missing image based on a predetermined criterion. Item 2. The image recording apparatus according to any one of Items 1 to 19. The image recording device according to claim 20, wherein the control unit estimates the cause of the abnormality based on the determined abnormality and specifies a recommended operation according to the result of the estimation. Equipped with a display
The image recording device according to claim 21, wherein the control unit displays the specified recommended operation on the display unit. Equipped with an operation reception section
The control unit
Based on the input operation received by the operation reception unit, the setting of the type of the missing image to be recorded is acquired.
The arrangement pattern of the missing image is determined based on the acquired setting, and the array pattern is determined.
At the time of recording the missing image, the driving unit that does not perform the recording operation of the recording element is determined according to the arrangement pattern.
The image recording apparatus according to claim 21 or 22, wherein the reference is adjusted based on the determined information relating to the sequence pattern and the determined abnormality. It has a plurality of recording elements, includes a recording operation unit that records an image on a medium by operating each of the plurality of recording elements, and the plurality of recording elements are grouped into a plurality of drive units. This is a method for detecting and controlling abnormalities in an image recording device.
For the original image data to be recorded, a detection image is set for each drive unit so that the recording element is not recorded, and a missing image in which the recording element of some of the set drive units is not recorded is recorded. An anomaly detection control method comprising a recording step. It has a plurality of recording elements, and includes a recording operation unit that records an image on a medium by operating each of the plurality of recording elements, and the plurality of recording elements are grouped into a plurality of drive units. The computer of the image recording device
For the original image data to be recorded, a detection image is set for each drive unit so that the recording element is not recorded, and a missing image in which the recording element of some of the set drive units is not recorded is recorded. A program characterized by functioning as a recording means.

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