BACKGROUND
1. Technical Field
[0001] The present invention relates to a recording apparatus that includes a transport
mechanism which supports and transports a recording medium by using a movable belt,
and to a recording method for the same.
2. Related Art
[0002] In the related art, recording apparatuses that include a transport mechanism which
supports and transports a recording medium by using a movable belt have been used.
Out of the recording apparatuses as described above, a recording apparatus that includes
a feeding unit which feeds the recording medium to the movable belt capable of supporting
the recording medium has been used. For example,
JP-A-2005-219845 discloses an image forming apparatus serving as the recording apparatus, which includes
a recording medium supply device serving as the feeding unit.
[0003] In a recording apparatus that includes a feeding unit which feeds a recording medium
to a movable belt capable of supporting the recording medium, depending on the type
and size of the recording medium or environmental conditions, in some cases, an excessive
load is applied to a feeding motor which drives the feeding unit. The description,
"the excessive load is applied to the feeding motor" means that an excessive force
is applied to the recording medium since the recording medium is pulled to the feeding
unit side from a movable belt. In some cases, the recording medium is damaged or wrinkles
are caused to occur thereon. Heat generation or breakdown due to the excessive load
applied to the feeding motor can be settled by taking a countermeasure of using a
feeding motor which has long durability or which is produced based on high torque
specifications. However, it is not possible to prevent the recording medium from being
damaged or wrinkled, and additionally the feeding motor becomes expensive. Therefore,
in the related art, in order to prevent the excessive load from being applied to the
motor (the excessive force from being applied to the recording medium), a load sensor
is disposed. In this manner, if the load sensor detects that the excessive load is
applied to the motor, a feedback control is performed by rotating the motor so as
to reduce the load.
[0004] However, in the above-described feedback control, the motor is rotated after the
excessive load is applied to the motor. Consequently, in some cases, an advantageous
effect cannot be sufficiently obtained when preventing the excessive load from being
applied to the motor. The load applied to the motor reaches a peak before the rotor
is rotated (moment when the force is applied to the motor left in a stopped state).
Therefore, even if the motor is rotated after detecting that the excessive load is
applied to the motor, the load is repeatedly applied thereto. Then, the load is gradually
accumulated in the motor, thereby resulting in a case where the motor becomes hot,
for example.
[0005] That is, in the related art, in the recording apparatus that includes a movable belt
capable of supporting a recording medium and a feeding unit which feeds the recording
medium to the movable belt, it is insufficient to prevent the excessive load from
being applied to the feeding motor of the feeding unit.
SUMMARY
[0006] An advantage of some aspects of the invention is to prevent an excessive load from
being applied to a feeding motor which drives a feeding unit, in a recording apparatus
that includes a movable belt capable of supporting a recording medium and the feeding
unit which feeds the recording medium to the movable belt.
[0007] According to an aspect of the invention, there is provided a recording apparatus
including a transport mechanism that can intermittently move a movable belt capable
of supporting a recording medium; a feeding unit that feeds the recording medium left
in a stretched state to the movable belt by receiving tension from the recording medium
in response to the intermittent movement of the movable belt; and a recording mechanism
that performs recording by causing a recording head to reciprocate in a direction
which intersects a transport direction of the recording medium. The feeding unit has
a feeding motor serving as a drive source and a load sensor of the feeding motor which
can detect a load based on the tension. When the load sensor detects the load which
is equal to or greater than a predetermined threshold value, a load reduction mode
for decelerating (reducing) an acceleration speed (acceleration)_during the intermittent
movement of the movable belt is performed.
[0008] Here, the aspect may include a configuration where it is possible "to feed the recording
medium to the movable belt in the stretched state of the recording medium". If it
is possible to feed the recording medium to the movable belt in the stretched state
of the recording medium, the aspect may include a configuration where it is also possible
to feed the recording medium to the movable belt in a slack state of the recording
medium.
[0009] In addition, the description, "that the recording medium left in a stretched state
is fed to the movable belt by receiving tension from the recording medium in response
to the intermittent movement of the movable belt" means that the recording medium
is fed to the movable belt after the tension from the recording medium is received.
That is, in addition to a configuration where the feedback control in the related
art can be performed, in a configuration where the force is applied to the recording
medium, that is, to a side opposite to a side where the recording medium is fed to
the movable belt in the feeding unit (configuration where a so-called back tension
is applied), the meaning also includes a configuration where the recording medium
is fed by the drive force of the movable belt by releasing the force of the opposite
side after the feeding unit receives the tension applied from the recording medium.
Furthermore, the meaning also includes a configuration where the recording medium
is caused to maintain the stretched state by using the weight of the recording medium
itself and the recording medium is fed by mainly using the drive force of the movable
belt.
[0010] In addition, the description, "decelerating the acceleration speed during the intermittent
movement of the movable belt" means decelerating (reducing) the acceleration speed
(acceleration) in a state where the movable belt is stopped and then is caused to
move during the intermittent movement of the movable belt. That is, it does not mean
decelerating (reducing) the maximum speed when the movable belt is moved.
[0011] In this case, the acceleration speed during the intermittent movement of the movable
belt is decelerated. Accordingly, it is possible to prevent the load from being applied
to the feeding motor during the intermittent movement. In addition, only the acceleration
speed during the intermittent movement of the movable belt is decelerated and the
maximum speed is not decelerated. In this manner, it is possible to prevent throughput
from being decreased.
[0012] In the recording apparatus, the recording medium may have a roll shape. The feeding
unit may feed the roll-shaped recording medium in response to a rotation drive of
the feeding motor. In the load reduction mode, during the intermittent movement of
the movable belt, for the recording medium having the largest roll diameter which
is supposed to be used and the recording medium having the smallest roll diameter
which is supposed to be used, the acceleration speed when the movable belt is moved
is decelerated so that the recording medium maintains the stretched state and the
load is smaller than the threshold value.
[0013] In this case, during the intermittent movement of the movable belt, for the recording
medium having the largest roll diameter which is supposed to be used and the recording
medium having the smallest roll diameter which is supposed to be used, the acceleration
speed when the movable belt is moved is decelerated so that the recording medium maintains
the stretched state. Therefore, even when using the recording medium having any roll
diameter which is supposed to be used, it is possible to feed the recording medium
in the stretched state of the recording medium.
[0014] In addition, in this case, during the intermittent movement of the movable belt,
for the recording medium having the largest roll diameter which is supposed to be
used and the recording medium having the smallest roll diameter which is supposed
to be used, the acceleration speed when the movable belt is moved is decelerated so
that the load is smaller than the threshold value. Therefore, even when using the
recording medium having any roll diameter which is supposed to be used, it is possible
to cause the load to be smaller than the threshold value.
[0015] The recording apparatus further includes a reception unit that receives information
of the roll diameter. Based on the information of the roll diameter which is received
by the reception unit, the acceleration speed in the load reduction mode is adjusted.
[0016] Here, the description, "information of the roll diameter" is not particularly limited
as long as the information relates to the roll diameter. For example, the information
includes information output from a sensor which can measure the roll diameter, information
of the roll diameter which is input from a user via a user interface and information
obtained by calculating the roll diameter input as an initial value and a transport
distance of the recording medium.
[0017] In this case, based on the information of the roll diameter which is received by
the reception unit, it is possible to adjust the acceleration speed in the load reduction
mode. Therefore, it is possible to accurately prevent the load from being applied
to the feeding motor during the intermittent movement.
[0018] The recording apparatus further includes a calculation unit that calculates the roll
diameter by using a rotation angle of the feeding motor and a movement distance of
the movable belt. The reception unit receives a calculation result of the calculation
unit.
[0019] In this case, based on the information of the roll diameter as the calculation result
of the calculation unit, it is possible to adjust the acceleration speed. Therefore,
it is possible to accurately prevent the load from being applied to the feeding motor
during the intermittent movement.
[0020] In the recording apparatus, based on a detection result of the load sensor, the acceleration
speed in the load reduction mode can be set.
[0021] In this case, based on the detection result of the load sensor, it is possible to
set the acceleration speed in the load reduction mode. Therefore, it is possible to
accurately prevent the load from being applied to the feeding motor during the intermittent
movement.
[0022] In the recording apparatus, the movable belt may be an adhesive belt.
[0023] In the recording apparatus having the adhesive belt (belt having a coated adhesive
which holds the recording medium by detachably adhering the recording medium on a
surface for setting the recording medium) serving as the movable belt, it is possible
to stably support the recording medium. Therefore, it is possible to preferably use
the adhesive belt as the movable belt.
[0024] In this case, since the recording medium can be stably supported, it is possible
to improve the quality of the recorded image.
[0025] In addition, in the recording apparatus including the adhesive belt, the recording
medium firmly adheres to the adhesive belt. Accordingly, there is a tendency to increase
the load which is applied to the feeding motor when the movable belt is moved. However,
in this case, even in the recording apparatus including the adhesive belt, it is possible
to prevent the excessive load from being applied to the feeding motor.
[0026] According to another aspect of the invention, there is provided a recording method
using a recording apparatus which includes a transport mechanism that can intermittently
move a movable belt capable of supporting a recording medium; a feeding unit that
feeds the recording medium left in a stretched state to the movable belt by receiving
tension from the recording medium in response to the intermittent movement of the
movable belt; and a recording mechanism that performs recording by causing a recording
head to reciprocate in a direction which intersects a transport direction of the recording
medium, in which the feeding unit has a feeding motor serving as a drive source and
a load sensor of the feeding motor which can detect a load based on the tension. The
method includes decelerating (reducing) an acceleration speed (acceleration) during
the intermittent movement of the movable belt, when the load sensor detects the load
which is equal to or greater than a predetermined threshold value.
[0027] In this case, the acceleration speed during the intermittent movement of the movable
belt is decreased. Therefore, it is possible to prevent the load from being applied
to the feeding motor during the intermittent movement. In addition, only the acceleration
speed during the intermittent movement of the movable belt is decelerated and the
maximum speed is not decelerated. In this manner, it is possible to prevent throughput
from being decreased.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Embodiments of the invention will now be described by way of example only with reference
to the accompanying drawings, wherein like numbers reference like elements.
Fig. 1 is a schematic side view illustrating an embodiment of a recording apparatus
of the invention.
Fig. 2 is a block diagram illustrating the embodiment of the recording apparatus of
the invention.
Fig. 3 illustrates a calculation method of a roll diameter of a recording medium in
the recording apparatus of the invention.
Figs. 4A and 4B illustrate a load reduction mode of the recording apparatus of the
invention.
Fig. 5 is a flowchart illustrating an embodiment of a recording method of the invention.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
Embodiment of Recording Apparatus, Figs. 1 to 4B
[0029] Hereinafter, a recording apparatus according to an embodiment of the invention will
be described in detail with reference to the accompanying drawings.
[0030] First, the recording apparatus according to the embodiment of the invention will
be described. The recording apparatus of the embodiment has a configuration including
an adhesive belt serving as a movable belt. However, the embodiment is not limited
to the above-described configuration. For example, an electrostatic adsorption type
of movable belt can also be used.
[0031] Fig. 1 is a schematic side view of a recording apparatus 1 according to an embodiment
of the invention.
[0032] The recording apparatus 1 of the embodiment includes a feeding unit 2 which can feed
a roll R1 of a recording medium P for recording. In addition, the recording apparatus
1 includes a transport mechanism 3 which transports the recording medium P in a transport
direction A by using an adhesive belt 10 serving as the movable belt. In addition,
the recording apparatus 1 includes a recording mechanism 4 which performs recording
by causing a recording head 7 to reciprocate in a scanning direction B which intersects
the transport direction A of the recording medium P. In addition, the recording apparatus
1 includes a cleaning mechanism 15 of the adhesive belt 10. In addition, the recording
apparatus 1 includes a winding mechanism 18 which has a winding shaft 17 for winding
the recording medium P and a cutter 16 for cutting the wound recording medium P.
[0033] The feeding unit 2 includes a rotary shaft 5 serving as a setting position of the
roll R1 of the recording medium P to be recorded. The feeding unit 2 is configured
to be capable of feeding the recording medium P to the transport mechanism 3 from
the roll R1 set in the rotary shaft 5 via a driven roller 6. When the recording medium
P is fed to the transport mechanism 3, the rotary shaft 5 is rotated in a rotation
direction C.
[0034] The rotary shaft 5 is rotatable by using a feeding motor 28 (refer to Fig. 2) as
a drive source, and has a load sensor 36 (refer to Fig. 2) which can detect a load
applied to the feeding motor 28 based on tension applied from the recording medium
P in response to an intermittent movement of the adhesive belt 10.
[0035] The transport mechanism 3 includes the adhesive belt 10 which performs transporting
by placing the recording medium P delivered from the feeding unit 2 thereon, a transport
roller 8 which moves the adhesive belt 10, and a driven roller 9. The recording medium
P is pressed to the adhesive belt 10 by a pressure roller 12 so that the recording
medium P adheres to and is placed on the adhesive belt 10. When the recording medium
P is transported, the transport roller 8 is rotated in the rotation direction C.
[0036] The recording mechanism 4 has a recording head 7, a carriage (not illustrated) on
which the recording head 7 is mounted, and a carriage motor 26 (refer to Fig. 2) which
causes the carriage to reciprocate in the scanning direction B. The scanning direction
B in Fig. 1 is a direction perpendicular to a paper surface in Fig. 1.
[0037] During the recording, the recording scan is performed by causing the recording head
7 to reciprocate. However, during the recording scan (during the movement of the recording
head 7), the transport mechanism 3 stops transporting the recording medium P. In other
words, during the recording, reciprocating scanning of the recording head 7 and transporting
of the recording medium P are alternately performed. That is, during the recording,
corresponding to the reciprocating scan of the recording head 7, the transport mechanism
3 intermittently transports the recording medium P.
[0038] The cleaning mechanism 15 of the adhesive belt 10 has a cleaning unit 13 configured
so that multiple cleaning rollers are connected to one another in a rotary shaft direction,
and a tray 14 which contains a cleaning agent for cleaning the cleaning unit 13.
[0039] The winding mechanism 18 is a mechanism for winding the recorded recording medium
P which is transported from the transport mechanism 3 via a driven roller 11. The
winding mechanism 18 can wind the recording medium P as a roll R2 by setting a winding
paper tube in the winding shaft 17 and gradually winding the recording medium around
the winding paper tube.
[0040] Next, an electrical configuration in the recording apparatus 1 of the embodiment
will be described.
[0041] Fig. 2 is a block diagram of the recording apparatus 1 of the embodiment.
[0042] A CPU 21 which performs overall controls of the recording apparatus 1 is disposed
in a control unit 20. A ROM 23 which stores various control programs executed by the
CPU 21, and a RAM 24 which can temporarily store data are connected to the CPU 21
via a system bus 22. In addition, the CPU 21 is connected to a head drive unit 25
for driving the recording head 7, via the system bus 22.
[0043] In addition, the CPU 21 is connected to a motor drive unit 32 for driving a carriage
motor 26, a belt motor 27, the feeding motor 28 and a winding motor 29, via the system
bus 22.
[0044] Here, the carriage motor 26 is a motor for moving the carriage on which the recording
head 7 is mounted. In addition, the belt motor 27 is a motor for driving the transport
roller 8. In addition, the feeding motor 28 is a rotary mechanism of the rotary shaft
5, and is a motor for driving the rotary shaft 5 in order to feed the recording medium
P to the transport mechanism 3. Then, the winding motor 29 is a drive motor for rotating
the winding shaft 17.
[0045] In addition, the CPU 21 is connected to a cutter drive unit 33 for driving a cutter
16 so as to cut the recording medium P, via the system bus 22.
[0046] Furthermore, the CPU 21 is connected to a monitor 34 and a control panel 35 which
are disposed in the recording apparatus 1, a load sensor 36 which can detect a load
applied to the feeding motor 28, and an interface 31 for inputting recording data
from an external device such as a PC via an input and output unit 30 for transmitting
and receiving data and signals.
[0047] The recording apparatus 1 of the embodiment has a load reduction mode in order to
reduce the load applied to the feeding motor 28. Then, a program for executing these
modes is stored in the ROM 23.
[0048] More specifically, in the load reduction mode, when the load sensor 36 detects the
load which is equal to or greater than a predetermined threshold value, the control
unit 20 controls to decelerate (reduce) the acceleration speed during the intermittent
movement of the adhesive belt 10, when the adhesive belt 10 is intermittently moved
several times from the second time (i.e. subsequent) movement.
[0049] In the recording apparatus 1 of the embodiment, the control unit 20 has a role as
a reception unit which receives information of a roll diameter of the roll R1 of the
recording medium P set on the rotary shaft 5. In the recording apparatus 1 of the
embodiment, it is possible to receive the information of the roll diameter which is
input from a user via a control panel 35 serving as a user interface. In addition,
it is also possible to receive the information of the roll diameter which is input
from an external device such as a PC via an interface 31. Furthermore, in the recording
apparatus 1 of the embodiment, the control unit 20 is configured to be capable of
calculating the roll diameter by using a rotation angle of the feeding motor 28 and
a movement distance of the adhesive belt 10. In other words, the control unit 20 performs
either or both a role serving as a calculation unit which calculates the roll diameter
by using the rotation angle of the feeding motor 28 and the movement distance of the
adhesive belt 10 and a role serving as a reception unit which receives a calculation
result of the calculation unit.
[0050] In addition, it is also possible to adopt a configuration where a sensor which can
measure the roll diameter is disposed in the recording apparatus 1 and the control
unit 20 can have as an input the information output from the sensor.
[0051] Based on the information of the roll diameter, the control unit 20 adjusts the acceleration
speed during the intermittent movement of the adhesive belt 10 in the load reduction
mode.
[0052] In addition, in the recording apparatus 1 of the embodiment, based on the detection
result of the load which is detected by the load sensor 36, it is possible to set
the acceleration speed during the intermittent movement of the adhesive belt 10 in
the load reduction mode. More specifically, the control of the control unit 20 enables
the acceleration speed to be automatically set based on the load. Based on the detection
result of the load which is detected by the load sensor 36, a user can manually set
the acceleration speed via the control panel 35 serving as the user interface.
[0053] Next, a calculation method of the roll diameter of the recording medium P in the
recording apparatus 1 of the embodiment will be described.
[0054] Fig. 3 illustrates the calculation method of the roll diameter of the roll R1 of
the recording medium P in the recording apparatus 1 of the embodiment.
[0055] The recording apparatus 1 of the embodiment is configured to be capable of measuring
a movement distance d of the adhesive belt 10 for one time based on the intermittent
transport of the recording medium P; and a rotation angle θ of the roll R1 (rotation
angle of the feeding motor 28) in response to the movement of the adhesive belt 10
for one time based on the intermittent transport of the recording medium P.
[0056] Here, the movement distance d of the adhesive belt 10 is equal to a product rθ of
a radius r of the roll R1 and the rotation angle θ of the roll R1. Therefore, the
radius r of the roll R1 can be expressed by d/θ. The control unit 20 calculates the
roll diameter of the roll R1 by using the above-described calculation method.
[0057] Next, the load reduction mode in the recording apparatus 1 of the embodiment will
be described.
[0058] Figs. 4A and 4B illustrate the load reduction mode of the embodiment.
[0059] Fig. 4A illustrates a movement speed V of the adhesive belt 10 and a load L applied
to the feeding motor 28 in the time corresponding thereto, when only the feedback
control in the related art is performed as the load reduction mode.
[0060] In Fig. 4A, the load L applied to the feeding motor 28 corresponding to the movement
start caused by the intermittent movement of the adhesive belt 10 reaches a peak,
and thus, the load L at the peak is equal to or greater than a threshold value T1.
[0061] The threshold value T1 is a predetermined threshold value based on an allowable load,
even when using the recording medium P having the largest roll diameter which is supposed
to be used, and even when using the recording medium P having the smallest roll diameter
which is supposed to be used. In addition, a threshold value T2 is a predetermined
threshold value based on a condition that the recording medium P maintains a stretched
state, even when using the recording medium P having the largest roll diameter which
is supposed to be used, and even when using the recording medium P having the smallest
roll diameter which is supposed to be used. That is, it is preferable that a range
of the load L be equal to or greater than the threshold value T2, and smaller than
the threshold value T1.
[0062] Fig. 4B illustrates the movement speed V of the adhesive belt 10 and the load L applied
to the feeding motor 28 in the time corresponding thereto, when performing the load
reduction mode of the embodiment. In Fig. 4B, an acceleration speed (acceleration)
which is a change rate in the movement speed V when a stopped state is transferred
to a movement state during the intermittent movement of the adhesive belt 10 is slower
than that of Fig. 4A.
[0063] In Fig. 4B, the belt motor 27 is driven so as to decelerate (reduce) the acceleration
speed (acceleration) during the intermittent movement of the adhesive belt 10. Therefore,
the load L at the peak is smaller than the threshold value T1. That is, the range
of the load L is equal to or greater than the threshold value T2, and smaller than
the threshold value T1, even at the peak. It is possible to decrease the value of
the load L at the peak as much as the acceleration speed during the intermittent movement
of the adhesive belt 10 is decelerated.
[0064] Instead of not performing the feedback control in the related art, the above-described
load reduction mode is performed together with the feedback control in the related
art. That is, in the above-described load reduction mode, the belt motor 27 is driven
so as to decelerate the acceleration speed during the intermittent movement of the
adhesive belt 10. However, together with the drive control of the belt motor 27, the
feedback control in the related art is performed on the feeding motor 28.
Embodiment of Recording Method, Fig. 5
[0065] Next, a recording method of the embodiment will be described.
[0066] Fig. 5 is a flowchart illustrating the recording method of the embodiment.
[0067] The recording method of the embodiment is an embodiment achieved by using the recording
apparatus 1 of the above-described embodiment.
[0068] In the recording method of the embodiment, if the recording apparatus 1 has recording
data input thereto, initially in step S110, the control unit 20 controls the adhesive
belt 10 to intermittently move. The control unit 20 causes the load sensor 36 to input
the load L applied to the feeding motor 28 at that time, and determines whether or
not the load L is equal to or greater than the threshold value T1.
[0069] In step S110, when it is determined that the load L is equal to or greater than the
threshold value T1, the process proceeds to step S120, and the control unit 20 has
input the rotation angle θ of the feeding motor 28 and the movement distance d of
the adhesive belt 10 in response to the intermittent movement of the adhesive belt
10.
[0070] In step S110, when it is determined that the load L is smaller than the threshold
value T1, the process proceeds to step S130, and the control unit 20 determines whether
or not the recording of the recording data input to the recording apparatus 1 is completed.
In step S130, when it is determined that the recording is not completed, the process
returns to step S110 until it is determined that the recording is completed. When
it is determined that the recording is completed, the recording method according to
the embodiment is completed.
[0071] If in step S120, the rotation angle θ of the feeding motor 28 and the movement distance
d of the adhesive belt 10 are input, the control unit 20 calculates the roll diameter
r of the recording medium in step S140.
[0072] Next, in step S150, based on the load detected by the load sensor 36, the control
of the control unit 20 determines that the acceleration speed during the intermittent
movement of the adhesive belt 10 should be set. At this time, the control unit 20
adjusts and sets the acceleration speed based on the roll diameter r calculated in
step S140.
[0073] Next, in step S160, a flag for performing the load reduction mode in the intermittent
movement of the adhesive belt 10 from the second movement is raised. Specifically,
in the load reduction mode, during the intermittent movement of the adhesive belt
10, the control unit 20 controls the drive of the belt motor 27 so as to cause the
adhesive belt 10 to intermittently move at the acceleration speed set in step S150.
[0074] If the flag for performing the load reduction mode is raised in step S160, in step
S170, it is determined whether or not the recording is completed. Then, the recording
is performed in the load reduction mode until it is determined that the recording
is completed. When it is determined that the recording is completed, the recording
method according to the embodiment is completed.
[0075] Although not shown in Fig. 5, the value of the load may be repeatedly measured and/or
the roll diameter may be repeatedly calculated (or measured) during recording to reset
the acceleration speed. In addition, it is possible to vary the acceleration with
the value of the detected load in addition to the value of the roll diameter.
[0076] The foregoing description has been given by way of example only and it will be appreciated
by a person skilled in the art that modifications can be made without departing from
the scope of the present invention.