BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
[0001] The present invention relates to a head diagnosis apparatus and a head diagnosis
method for printer, and more particularly, is applicable to a color printer with thermal
recording system.
DESCRIPTION OF THE RELATED ART
[0002] A color printer of above-mentioned type comprises a thermal head having a plurality
of heat generators arranged in line on its head surface perpendicular to the traveling
direction of a printing paper. The thermal head is pressed against a platen with an
ink ribbon and the printing paper interposed in between. In this state, the respective
heat generators are selectively electrified on the basis of a predetermined image
printing signal to generate heat from the selected heat generators which thermal-transfer
a variety of pigments coated on the ink ribbon onto the surface of the printing paper.
In this way a color image can be printed on the surface of the printing paper.
[0003] In the conventional color printer as mentioned above, however, when the thermal head
suffers external damages or electrical trouble on its head surface during a thermal
transfer operation, some of the plurality of heat generators arranged on the head
surface of the thermal head remain open, when they should be closed. This prevents
the current from flowing, or causes a short-circuit leaving the current to continuously
flow.
[0004] In this case, on a printing paper after the thermal transfer operation leave white
lines along its traveling direction, formed at corresponding positions where heat
generators did not operate; or black lines along its traveling direction formed at
corresponding positions to heat generators where current is always flowing to cause
a continuous heat generated state.
[0005] Consequently, if an operator recognizes any printing errors on a printing paper,
the operator needs to examine the condition of the thermal head, and accordingly replace
the failed thermal head with a new one. However, when a large amount of printing is
automatically performed using such a conventional color printer, any trouble in a
thermal head would result in printing errors on a huge amount of printing papers.
This causes producers to incur a larger scale of printing paper loss.
SUMMARY OF THE INVENTION
[0006] In view of the foregoing, an object of the invention is to provide a head diagnosis
apparatus and a head diagnosis method for printer which are capable of efficiently
preventing printing errors.
[0007] The foregoing object and other objects of the invention have been achieved by the
provision of a head diagnosis apparatus for diagnosing the condition of a thermal
head, which comprises: measuring means for measuring respectively the resistance value
of a plurality of heat generation resistive elements arranged on a head surface of
the thermal head; storage means for storing the resistance of each of the heat generation
resistive elements measured by the measuring means; calculating means for calculating
a change amount of the resistance of each of the heat generation resistive elements
based on the resistance value of each of the heat generation resistive elements measured
in the past which is stored in the storage means, and the resistance value of each
of the heat generation resistive elements measured by the measuring means; and diagnosis
means for judging the electrification state of each of the heat generation resistive
elements based on the calculation result of the calculating means to diagnose the
condition of the thermal head in accordance with the judgement.
[0008] As a result, it can be readily judged whether each heat generation resistive element
is at present in a normal electrification state or is currently exhibiting an abnormal
electrification state, or whether it is likely to fall into a fault in future, before
actually entering the printing stage.
[0009] Also, in the present invention, a head diagnosis method for diagnosing the condition
of a thermal transfer measures the resistance value of a plurality of heat generation
resistive elements arranged on a head surface of the thermal head, and then calculates
a change amount of the resistance value of each heat generation resistive element
on the basis of the resistance value of each heat generation resistive element measured
in the past and the resistance value of each heat generation resistive element measured
at the current time to judge a electrification state of each heat generation resistive
element on the basis of the calculation result, and to diagnose the condition of the
thermal head in accordance with the judgement.
[0010] As a result, it can be readily judged whether each heat generation resistive element
is currently in a normal electrification state or is currently exhibiting an abnormal
electrification state, or whether it is likely to fall into a fault in future before
actually entering the printing stage.
[0011] The nature, principle and utility of the invention will become more apparent from
the following detailed description when read in conjunction with the accompanying
drawings in which like parts are designated by like reference numerals or characters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the accompanying drawings:
Fig 1 is a schematic plan view and cross-sectional view used for explaining the structure
of a thermal head;
Fig. 2 is a cross-sectional view illustrating the thermal head of Fig. 1 having a
protective film suffering a flaw;
Fig. 3 is a cross-sectional view illustrating the thermal head of Fig. 1 having a
protective film suffering thunderbolt;
Fig. 4 is a graph illustrating the relation between the resistance value of a heat
generation resistive element and the time;
Fig. 5 is a schematic lateral view illustrating the structure of a card printer according
to an embodiment;
Fig. 6 is a schematic view used for explaining an ink ribbon;
Fig. 7 is a block diagram illustrating the circuit configuration of a color image
printing part;
Fig. 8 is a block diagram illustrating the internal configuration of a thermal head;
Fig. 9 is a block diagram illustrating the configuration of a head diagnosis part
illustrated in Fig. 7;
Fig. 10 is a block diagram illustrating in detail the configuration of the head diagnosis
part of Fig. 9;
Fig. 11 is a graph illustrating the relation between the resistance value of a heat
generation resistive element and a voltage based on differential voltage data;
Fig. 12 is a flow chart used for explaining a head diagnosis processing procedure;
and
Fig. 13 is a flow chart used for explaining a head diagnosis processing procedure.
DETAILED DESCRIPTION OF THE EMBODIMENT
[0013] Preferred embodiments of this invention will be described with reference to the accompanying
drawings:
[0014] Generally, as illustrated in Fig. 1A, a thermal head 1 has a plurality of heat generators
2A to 2N (N is a predetermined number) arranged in line on a head surface 1A perpendicularly
to the traveling direction of a printing paper (not shown). Each of the heat generators
2A to 2N has a heat generation resistive element 5 on a protrusion of a glass layer
4 laminated on a ceramic substrate 3 as illustrated in a cross-sectional view taken
along a line A-A' across the head surface 1A in Fig. 1B. The heat generation resistive
element 5, together with electrodes 6 formed at one end and the other end thereof,
is overlaid by a protective film 7 made of a glass material.
[0015] If relatively hard dust or the like gets in between the head surface 1A of the thermal
head 1 and a platen (not shown) to damage the heat generators 2A to 2N on the head
surface 1A, the protective film 7 of the heat generators 2A to 2N corresponding to
the damaged portion is likely to suffer a flaw 7A as illustrated in Fig. 2. In this
event, since stress concentrates on the flaw 7A in the protective film 7, the heat
generation resistive element 5 changes its resistance value. When any of the heat
generators 2A to 2N is gravely damaged, an associated heat generation resistive element
5 is opened to break a current flow, resulting in a white line drawn on a printing
paper along its traveling direction.
[0016] On the other hand, if static electricity is generated on the head surface 1A of the
thermal head 1 during a printing operation to cause a thunderbolt, a pinhole 7B is
likely to be formed through the protective film 7 of the heat generators 2A to 2N,
which was stuck by the thunderbolt, as illustrated in Fig. 3. In this event, since
moisture, ions or the like can get in or out through the pinhole 7B of the protective
film 7, the heat generation resistive element 5 changes its resistance value. If a
stronger thunderbolt is generated, a current always flows into the heat generation
resistive element 5, resulting in a black line drawn on a printing paper along its
traveling direction.
[0017] Here, Fig. 4 illustrates the relation between the resistance value of the heat generation
resistive element 5 and the time change. In Fig. 4, a characteristic curve F1 of the
heat generation resistive element 5 has a characteristic in which the resistance value
of the heat generation resistive element 5 is R
0 at time T
0, once decreases over time, and then gradually increases.
[0018] Actually, if any of the heat generators 2A to 2N flaws at time T
1 to open its heat generation resistive element 5, the resistance value of the heat
generation resistive element 5 slightly increases and causes a slightly upward shift
of the characteristic curve F1, resulting in a characteristic curve F1A. On the other
hand, if a thunderbolt is generated in the heat generators 2A to 2N at time T
1 to short-circuit a heat generation resistive element 5, the resistance value of the
heat generation resistive element 5 slightly lowers and causes a slightly downward
shift of the characteristic curve F1, resulting in a characteristic curve F1B.
[0019] It is therefore possible to judge whether or not a heat generation resistive element
5 exhibits an abnormal electrification state by detecting an increasing or decreasing
resistance value of the heat generation resistive element 5 to consequently diagnose
the condition of the thermal head 1.
(2) General Configuration of Card Printer
[0020] In Fig. 5, a card printer, to which the present invention is applied, is generally
designated by reference numeral 10. A card material 13 inserted into the card printer
from a card insertion slot 11A of a housing 11 through cleaning rollers 12A, 12B is
carried by the card carrier 14 along a carrying path CR.
[0021] The card material 13 employed in this embodiment conforms to the so-called International
Organization for Standardization (ISO) standard. Specifically, the card material 13
has a magnetic stripe formed on one side along a longitudinal edge, and an Integrated
Circuit (IC) memory embedded in the other side at a predetermined position near a
front end of the card material 13.
[0022] The card carrier 14 is composed of first and second carrying sections 14A, 14B disposed
on front and back sides of a platen 15 along the carrying path CR. The first and second
carrying sections 14A, 14B are provided with four pairs of carrying rollers 16A to
19A and 16B to 19B, respectively, which are mounted on axes for any rotation along
the carrying path CR at predetermined intervals.
[0023] The upper carrying rollers 16A to 19A are rotated in the same direction in association
with each other according to the rotation of a driving motor (not shown), while the
lower carrying rollers 16B to 19B are kept in contact with the corresponding upper
carrying rollers 16A to 19A, so that the lower carrying rollers 16B to 19B are rotated
in the direction opposite to the rotation of the upper carrying rollers 16A to 19A.
With the structure as mentioned, the card material 13, inserted between the upper
and lower carrying rollers 16A to 19A and 16B to 19B, is carried forward or backward
along the carrying path CR in accordance with the rotation of the upper carrying rollers
16A to 19A.
[0024] A color image printing part 20 is disposed at a predetermined position opposing the
platen 15 above the card carrier 14. In the color image printing part 20, a head holding
mechanism 22 including a head part 21 is extended in a direction in which a thermal
head 23 supported at a leading end of the head part 21 is pressed against the platen
15, and is retracted in a direction in which the thermal head 23 is brought away from
the platen 15.
[0025] Actually, the head holding mechanism 22 is constructed of a cam 25 which rotates
on a driving shaft 24 of a head motor (not shown), and a link mechanism engaged with
the cam 25 and including a shifter member 28, a connecting member 29 and a supporting
member 30 with a rotating shafts 26, 27 as fixed links.
[0026] Thus, in this head holding mechanism 22, the link mechanism 26 to 30 engaged with
the cam 25 is extended in response to the driving of the head motor in a printing
mode in order to press the thermal head 23 against the platen 15. After terminating
the printing mode, the link mechanism 26 to 30 engaged with the cam 25 is retracted
in response to the driving of head motor in order to bring the thermal head 23 away
from the platen 15.
[0027] In an image printing mode, the color image printing part 20 drives the head holding
mechanism 22 to press the thermal head 23 against the platen 15 with a roll-shaped
ink ribbon 33, supported by a supply reel 31 and a wind-up reel 32, and a card material
13 positioned on the platen 15 interposed in between. Subsequently, the thermal head
23 is heated in this state based on a predetermined image printing signal to thermal-transfer
the ink on the ink ribbon 33 onto one side of the card material 13.
[0028] In this case, the roll-shaped ink ribbon 33 is accommodated in a ribbon cassette
34. The ribbon cassette 34 is loaded capable of being removed between the color image
printing part 20 and the platen 15 through a cassette insertion slot (not shown) formed
on a side wall of the housing 11.
[0029] The ink ribbon 33 includes color pigments of yellow Y, magenta M, cyan C and black
K, each coated over at a predetermined length thereon as a pigment for one piece of
the card material 13, followed by a film-like sheet L, as illustrated in Fig. 6. Further,
a predetermined mark (not shown) is impressed at the head position for each page of
the ink ribbon 33 in order that the head position of the ink ribbon 33 can be located
by detecting the mark by an optical sensor (not shown) disposed on a running path
of the ink ribbon 33.
[0030] The supply real 31 is provided with a torque limiter (not shown) for applying a predetermined
torque during rotation, so that the ink ribbon 33 is always applied with a back tension.
Further, an optical sensor (not shown) is disposed near the supply real 31 for detecting
the diameter of the rolled ink ribbon 33. And by detecting the tension of the ink
ribbon 33, the winding state of the wind-up reel 32 can be controlled.
[0031] Below the carrying path CR in the second carrier 14B, a magnetic recording/reproducing
part 40 is disposed. A magnetic head 41 is exposed on the carrying path CR so as to
be positioned side by side with the lower carrying roller 18B and contacted the upper
carrying roller 18A only during recording and reproduction. And the magnetic head
41 is concealed below the carrying path CR other than during recording and reproduction.
[0032] Thus, the magnetic recording/reproducing part 40 records information based on a predetermined
recording signal on magnetic stripes (not shown) formed on one side of the card material
13, with the magnetic head 41 exposed on the carrying path CR. Subsequently, the magnetic
recording/reproducing part 40 reproduces the recorded information to judge whether
or not any recording errors are found on the magnetic stripes.
[0033] Optical sensors 42, 43, 44 of photo-interrupter type are disposed on front and back
sides of the first carrying section 14A and in front of the second carrying section
14B in order that the presence or absence of the card material 13 carried along the
carrying path CR is detected.
[0034] Behind the second carrier 14B and near a card discharge slot 11B of the housing 11,
a rotary carrier 45 is disposed along the carrying path CR. The rotary carrier 45
has a rotary mechanism 46 supported on a rotating shaft 47 on which it can rotate
in a direction indicated by an arrow
r or in the opposite direction. The rotary mechanism 46 includes a first pair of flipper
rollers 48A, 48B and a second pair of flipper rollers 49A, 49B. And each pair is capable
of any rotation keeping a symmetrical position with the rotation shaft 47 in between.
[0035] The flipper rollers 48A, 49A on an upper side each rotate in the same direction in
conjunction with the rotation of the driving motors (not shown). The flipper rollers
48B, 49B on a lower side are each pressed against the corresponding flipper rollers
48a, 49A on the upper side, and rotate in the opposite direction to the rotation of
the flipper rollers 48A, 49A. With the structure as mentioned, the card material 13
inserted between the first pair of flipper rollers 48A, 48B and/or between the second
pair of flipper rollers 49A, 49B is carried forward or backward on the carrier path
CR according to the rotation of the flipper rollers 48A, 49A on the upper side.
[0036] In this way, the rotary carrier 45 holds the card material 13 carried from the second
carrying section 14B in the rotary mechanism 46, and rotates the rotary mechanism
46 together with the card material 13 held therein over a predetermined angular distance
in the direction indicated by the arrow
r or in the opposite direction as required to position the rotary mechanism 46, so
that the card material 13 is delivered in a predetermined direction determined by
positioning.
[0037] An IC recording/reproducing part 50 is disposed near the rotary carrier 45. As the
card material 13 delivered from the rotary carrier 45 is inserted into an insertion
slot 50A of the IC recording/reproducing part 50, each terminal of an IC memory (not
shown) disposed on the other side of the card material 13 is brought into contact
with an interface connector (not shown). As a result, the IC recording/reproducing
part 50 records information based on a predetermined recording signal, and then reproduces
the recorded information to judge whether or not any recording errors are found in
the IC memory.
[0038] An unacceptable card tray 51 is disposed near the rotary carrier 45. A card material
13, which has been judgeded that recording errors have been found in the magnetic
recording/reproducing part 40 or in the IC recording/reproducing part 50, is discharged
from the rotary carrier 45 through an inlet slot 51A to the unacceptable card tray
52.
[0039] Conversely, the rotary carrier 45 delivers a card material 13, which has been determined
that no recording errors have been found in the magnetic recording/reproducing part
40 or in the IC recording/reproducing part 50, to an external card tray (not shown)
through a card discharge slot 11B of the housing 11.
[0040] In addition, a first optical sensor 52 and a second optical sensor 53, both of a
photo-interrupter type, are disposed outside the first pair of flipper rollers 48A,
48B and outside the second pair of flipper rollers 49A, 49B (i.e., both in the centrifugal
direction of the rotating shaft 47), respectively, for detecting the presence or absence
of the card material 13 sent thereto along the carrying path CR.
[0041] For reference, in this card printer 10, the card carrier 14, the color image printing
part 20, the magnetic recording/reproducing part 40, the rotary carrier 45 and the
IC recording/reproducing part 50 are each driven in predetermined states in accordance
with the control of a CPU 61 which responds to instructions from a host computer 60
(Fig. 7), later described.
(3) Printing Processing in Color Image Printing Part
[0042] Fig. 7 illustrates the circuit configuration of the color image printing part 20.
As predetermined image printing data D
P is supplied from a host computer 60 through an interface (I/F) 62 and a Computer
Interface (C/I) driver 63, a memory controller 64 writes a one-frame portion of the
image printing data D
CP into corresponding frame memories 65 to 69 as color image printing data D
PY (yellow Y), D
PM (magenta M), D
PC (cyan C) and D
PK (black K), corresponding to the respective colors, and laminate data P
DL (film-like sheet L) in accordance with the control of the CPU 61.
[0043] Next, the memory controller 64 reads the color image printing data D
PY, D
PM, D
PC, D
PK and the laminate data D
PL from the respective frame memories 65 to 69 at predetermined timing in accordance
with the control of the CPU 61. Then the color image printing data D
PY, D
PM, D
PC are transmitted to color adjustment parts 70 to 72, respectively, and the color image
printing data D
PK and the laminate data D
PL are transmitted to respective input terminals of a selector 73.
[0044] The color adjustment parts 70 to 72, which are provided with a color conversion table
(not shown) having standard image printing characteristics for each color, perform
color adjustment for each color in accordance with an adjustment curve before and
after color matching processing, and transmit resulting color image printing data
D
PY1, D
PM1, D
PC1 to a masking part 74.
[0045] The masking part 74 separates unnecessary data from the supplied color image printing
data D
PY1, D
PM1, D
PC1 and transmits resulting color image printing data D
PY2, D
PM2, D
PC2 to the other input terminal of the selector 73.
[0046] The selector 73 sequentially transmits data selected as required from the respective
color image printing data D
PY2, D
PM2, D
PC, D
PK and the laminate data D
PL, supplied thereto, based on the control of the CPU 61 to a gamma correction part
75. The gamma correction part 75 performs a color-strength electrification time conversion
with a predetermined heat correction coefficient which has been set on the basis of
the control of the CPU 61, and supplies a head controller 76 with print image data
D
T resulting from the conversion.
[0047] The head controller 76, which is disposed in the head holding mechanism 22, converts
the print image data D
T to a current signal D
I which is then provided to the thermal head 23. As a result, a plurality of heat generation
resistive elements arranged on a head surface (not shown) of the thermal head 23 are
heated in accordance with the current signal D
I. Consequently, the color image printing part 20 can heat the head surface of the
thermal head 23 based on the image printing data D
P, and print a desired color image in accordance with the image print data D
P based on the heated head on one or the other side of the card material 13.
[0048] The CPU 61 can move the thermal head 23 in the head part 22 closer to or away from
the platen 15 by controlling the driving of mechanical controller 77 including the
aforementioned cam 25 and the link mechanism 26 to 30, described in Fig. 5. The CPU
61 also sends control instructions to respective circuits through a bus 78.
[0049] In addition to the configuration described above, the color image printing part 20
is provided with a head diagnosis part 80 between the CPU 61 and the thermal head
23. The head diagnosis part 80 sequentially measures the resistance value of each
heat generation resistive element one by one for a plurality of heat generators (not
shown) disposed on the head surface of the thermal head 23 in order to permit judgement
as to whether or not the resistance value of each heat generation resistive element
is normal based on the results of the measurements.
[0050] The CPU 61 first sends a switching signal S1 to the head diagnosis part 80 to selectively
switch the head diagnosis part 80 to a printing mode or a head diagnosis mode. In
this event, for selecting the head diagnosis mode, the head controller 76 sends electrification
setting data D
E to the thermal head 23 for sequentially measuring one by one the resistance value
of the heat generation resistive elements corresponding to the respective heat generators
of the thermal head 23 in accordance with the control of the CPU 61.
[0051] As illustrated in Fig. 8, the thermal head 23 has a plurality of heat generators
23H
1 to 23H
N (N is for example equal to 640) on the head surface. The heat generators 23H
1 to 23H
N are connected by a latch circuit 90 to a plurality of registers 91R
1 to 91R
N, which constitute a serial-type shift register.
[0052] Image printing data D
I are orderly stored one by one in the plurality of registers 91R
1 to 91R
N in synchronization with a clock CL inputted thereto. When the image printing data
D
I have been stored in all of the registers 91R
1 to 91R
N, all outputs of the 91R
1 to 91R
N are applied in parallel to the latch circuit 90.
[0053] Respective heat generators 23H
1 to 23H
N are connected to a common power supply 94 through heat generation resistive elements
93R
1 to 93R
N which basically comprise transistors 92Q
1 to 92Q
N, respectively, each of which has a collector connected to a load resistor. All emitters
are connected to a common terminal (not shown) in the head diagnosis part 80. And
bases are connected to each output stage of the latch circuit 90 through load resistors
95R
1 to 95R
N, respectively.
[0054] The latch circuit 90, upon receiving the electrification setting data D
E supplied from the head controller 76, sequentially electrifies and connects one by
one between a heat generator 23H
I (I is an arbitrary number satisfying 1≦I≦N) and a corresponding register 91R
I, thereby sequentially turning on a transistor 92Q
I in the heat generator 23H
I. This causes a voltage of the power supply 94 to be applied to each heat generator
23H
I, and a collector-emitter current to flow through a corresponding heat generation
resistive element 93R
I into the head diagnosis part 80.
[0055] The head diagnosis part 80 has a configuration based on an operational amplifier
100, as illustrated in Fig. 9, which has one input terminal connected to the thermal
head 23, to a drain of a power Metal Oxide Semiconductor (MOS) Field Effect Transistor
(FET) 101 and to a load resistor 102R, and the other input terminal is connected to
a reference voltage source 103.
[0056] A source of the power MOS FET 101, the load resistor 102R and the reference voltage
source 103 are connected to a ground GND. The power MOS FET 101 is used as a switching
circuit which turns on or off in response to "H" or "L" level of the switching signal
S1 supplied from the CPU 61 to the gate thereof.
[0057] More specifically, in the printing mode, when the CPU 61 supplies the power MOS FET
101 with the switching signal S1 at "H" level to cause the power MOS FET 101 to turn
on, current supplied from each heat generator 23H
I flows into the ground GND as a drain-source current of the power MOS FET 101. For
this reason, the current supplied from each heat generator 23H
I does not flow through an intermediate connection point P1 between the one input terminal
of the operational amplifier 100 and the load resistor 102R.
[0058] In the head diagnosis mode, on the other hand, when the CPU 61 supplies the power
MOS FET 101 with the switching signal S1 at "L" level to cause the power MOS FET 101
to turn OFF, the current supplied from each heat generator 23H
I does not flow through the drain-source of the power MOS FET 101 but flows through
the intermediate connection point P1 into the one input terminal of the operational
amplifier 100 as well as through the load resistor 102R to the ground GND.
[0059] Responsively, the operational amplifier 100 calculates the difference in potential
between the one input terminal and the other input terminal, subsequently converts
the differential voltage to a digital form through an analog-to-digital (A/D) converter
circuit 104, and sends the digital product to the CPU 61 as differential voltage data
D
VS.
[0060] The operational amplifier 100 is composed of a differential amplifier circuit 110
as a basic component, and a current regulating circuit 111 connected thereto, as illustrated
in Fig. 10. The differential amplifier circuit 110 has a pair of PNP transistors Q1,
Q2, which have their bases connected to the power supply 94 through a heat generation
resistive element 93R
I of the heat generator 23H
I and a load resistor 113R which has the same resistance value as the heat generation
resistive element 93R
I, respectively.
[0061] An intermediate connection point P2 between the base of the transistor Q2 and the
load resistor 113R is connected to an end of a voltage dividing resistor 114R which
has the same resistance value as the load resistor 102R and has the other end connected
to the ground GND. The reference voltage source 103 mentioned above in connection
with Fig. 9 is actually composed of the resistors 113R, 114R connected in series between
the power supply 94 and the ground GND, and the differential amplifier 110 connected
to the intermediate connection point P2 between the resistors 113R and 114R.
[0062] The transistor Q1 has a collector connected to the ground GND, while the transistor
Q2 has a collector connected through a voltage dividing resistor 115R to the ground
GND. An intermediate connection point P3 between the collector of the transistor Q2
and the resistor 115R is connected to the A/D converter circuit 104.
[0063] The current regulating circuit 111 has a pair of PNP transistors Q3, Q4, which have
their emitters connected commonly to the power supply 94 through load resistors 116R,
117R. Bases of the transistors Q3, Q4 are connected to one end of a capacitor C1,
the other end of which is connected to the power supply 94, and also connected through
a load resistor 118R to the ground GND. Thus, the current regulating circuit 111 is
configured in order that the same current as that flowing into the transistor Q4 flows
into the transistor Q3.
[0064] The transistor Q3 has its collector connected through load resistors 119R, 120R commonly
to emitters of the transistors Q1, Q2 in the differential amplifier circuit 110, respectively.
[0065] In the configuration illustrated in Fig. 10, the power MOS FET 101 is in OFF state
in the head diagnosis mode, wherein a currents flows into the intermediate connection
point P1 from the power supply 94 through the heat generation resistive element 93R
I of the heat generator part 23H
I, thereby causing a potential difference V
I to be generated at the intermediate connection point P1, as expressed by the following
expression (1):

where a voltage value of the power supply 94 is V
H; the resistance value of the heat generation resistive element 93R
I is r
I; and the resistance value of the load resistor 102R is r
M.
[0066] In this event, if the resistance value r
I of the heat generation resistive element 93R
I falls within a predetermined set standard range, the intermediate connection points
P1, P2 both have the same potential difference, so that a differential voltage value
outputted from the differential amplifier circuit 110 through the intermediate connection
point P3 is applied as it is to the A/D converter circuit 104.
[0067] Here, if the resistance value r
I of the heat generation resistive element 93R
I is higher than the set standard range to reduce the potential at the intermediate
connection point P1, a current flowing into the base of the transistor Q1 decreases,
causing an emitter-collector current of the transistor Q1 to decrease. At this point,
since a current flowing from the current regulating circuit 111 is regular, a reduced
portion of the emitter-collector current of the transistor Q1 is added to an emitter-collector
current of the transistor Q2 to increase the same. As a result, the potential difference
at the intermediate connection point P3 is increased and applied to the A/D converter
circuit 104.
[0068] On the other hand, if the resistance value r
I of the heat generation resistive element 93R
I is lower than the set standard range to increase the potential at the intermediate
connection point P1, a current flowing into the base of the transistor Q1 increases,
causing the emitter-collector current of the transistor Q1 to increase. At this point,
since a current flowing from the current regulating circuit 111 is regular, the increased
emitter-collector current of the transistor Q1 is subtracted from the emitter-collector
current of the transistor Q2 to reduce the same. As a result, the potential difference
at the intermediate connection point P3 is reduced and applied to the A/D converter
circuit 104.
[0069] In this way, when the thermal head 23 is applied with the electrification setting
data D
E, a current flows through the heat generation resistive element 93R
I disposed in each heat generator 23H
I within the thermal head 23 to generate a drop voltage V
I across the heat generation resistive element 93R
I. The head diagnosis part 80 calculates a difference between the voltage V
I and the voltage V
M of the reference voltage source 103 and converts the calculated difference to a digital
form to produce differential voltage data D
VS which is sent to the CPU 61.
[0070] The CPU 61 also contains a predetermined conversion table (not shown), such that
the resistance value r
I of the heat generation resistive element 93R
I corresponding to the differential voltage data D
VS can be retrieved from the conversion table based on a characteristic curve F2 which
represents the resistance value r
I of the heat generation resistive element 93R
I in proportion to the voltage of the differential voltage data D
VS, as illustrated in Fig. 11.
[0071] Consequently, the CPU 61 sequentially retrieves from the conversion table the resistance
value r
I of the heat generation resistive element 93R
I corresponding to the differential voltage data D
VS sequentially supplied from the head diagnosis part 80 based on the differential voltage
data D
VS, and then stores the retrieved resistance value r
I in a flash memory 81.
[0072] The flash memory 81 previously stores initial resistance value (the resistance value
measured when they were manufactured) r
0I of all the heat generation resistive elements 93R
I, and also stores the resistance value r
I of all the heat generation resistive elements 93R
I measured in the previous head diagnosis mode.
[0073] Here, if the CPU 61 judges that the resistance value r
I of a heat generation resistive element 93R
I corresponding to a voltage of differential voltage data D
VS supplied from the head diagnosis part 80 is out of a predetermined range with respect
to the characteristic curve F2 illustrated in Fig. 11, the CPU 61 sends a printing
reference signal S2 to the host computer 60 through the C/I driver 63 and the interface
62 as required (Fig. 7).
[0074] The host computer 60, upon receipt of the printing reference signal S2, judges whether
or not a heat generator 23H
I within the thermal head 23 exhibiting an abnormal electrification state actually
is used for an image printing area based on image printing data D
P within an image to be printed, and sends a diagnosis notification signal S3 in accordance
with the result of the judgement to the CPU 61 through the interface and the C/I driver.
[0075] In this event, the host computer 60 sends to an error display part 82 an error signal
S4 indicating that the thermal head 23 has failed, when the result of the judgement
is negative, thereby causing the error display part 82 to display on its display screen
that the thermal head 23 has failed.
(4) Processing Procedure for Diagnosing Thermal Head
[0076] The CPU 61 in the color image printing part 20 executes a head diagnosis processing
procedure RT1 illustrated in Figs. 12, 13 based on the control of the host computer
60, to diagnose whether or not each of heat generators 23H
1 to 23H
N, arranged on the surface of the thermal head 23, exhibits an abnormal electrification
state by sequentially measuring one by one the resistance value of the heat generation
resistive elements 93R
1 to 93R
N within the respective heat generators 23H
1 to 23H
N.
[0077] First, the CPU 61 enters the head diagnosis processing procedure RT1 illustrated
in Fig. 12 from step SP0 in accordance with the control of the host computer 60, before
starting a printing operation or after ending a printing operation, that is, when
not in the printing mode. At subsequent step SP1, the CPU 61 turns off the power MOS
FET 101 to set the head diagnosis mode. Then, the CPU 61 proceeds to step SP2, where
the CPU 61 sequentially electrifies one by one the heat generation resistive elements
93R
1 to 93R
N in the plurality of heat generators 23H
1 to 23H
N of the thermal head 23.
[0078] Subsequently, the CPU 61 proceeds to step SP3, where for one of the heat generators
23H
I (1≦I≦N), a current flowing into the intermediate connection point P1 from the power
supply 94 through the head generation resistive element 93R
I and a current flowing from the reference voltage source 103 are applied to one input
terminal and the other input terminal, respectively, of the operational amplifier
100 in the head diagnosis unit 80 illustrated in Fig. 9, to force the operational
amplifier 100 to calculate the difference between the voltage V
I at the intermediate connection point P1 and the voltage V
M of the reference voltage source 103. Then, the CPU 61 receives the differential voltage.
[0079] Next, at step SP4, the CPU 61 retrieves the resistance value r
I of the heat generation resistive element 93R
I corresponding to the received differential voltage in accordance with the predetermined
conversion table (not shown) stored therein.
[0080] At step SP5, the CPU 61 determines whether or not the retrieved resistance value
r
I of the heat generation resistive element 93R
I is within a predetermined range with respect to the characteristic curve F2 in the
aforementioned Fig. 11.
[0081] If a negative result is returned at step SP5, this means that the heat generation
resistive element 93R
I is in an open state or in a short-circuited state, in which case the CPU 61 proceeds
to step SP6, where it further judges whether or not the resistance value r
I is higher than the predetermined range with respect to the characteristic curve F2.
[0082] If an affirmative result is returned at step SP6, this means that the heat generation
resistive element 93R
I is in a short-circuited state, in which case the CPU 61 proceeds to step SP7 (Fig.
13), later described, where it notifies the host computer 60 of the fact that the
heat generation resistive element 93R
I exhibits an abnormal electrification state.
[0083] On the other hand, if a negative result is returned at step SP6, this means that
the heat generation resistive element 93R
I is in an open state, in which case the CPU 61 proceeds to step SP8, where the CPU
61 forces the host computer 60 to judge whether or not the heat generation resistive
element 93R
I is actually a heat generation resistive element R
I of a heat generator 23H
I falling into an image printing area based on image printing data D
P within an image to be printed.
[0084] If an affirmative result is returned at step SP8, this means that the heat generator
23H
I does affect the contents to be printed on a card material 13, in which case the CPU
61 proceeds to step SP7, where it notifies the host computer 60 of the fact that the
heat generation resistive element 93R
I exhibits an abnormal electrification state, as mentioned above.
[0085] On the other hand, if a negative result is returned at step SP8, the CPU 61 determines
that the heat generation resistive element 93R
I is in a normal electrification state since the contents to be printed on the card
material 13 will not be affected by the heat generation resistive element 93R
I even if it is in an open state. Then, the CPU 61 proceeds to step SP9 (Fig. 13),
later described.
[0086] At step SP5, if an affirmative result is returned, this means that the resistance
value of the heat generation resistive element 93R
I retrieved from the conversion table is within the predetermined range with respect
to the characteristic curve F2, in which case the CPU 61 proceeds to step SP10, where
it reads from the flash memory 81 the resistance value r
I' of the heat generation resistive element 93R
I measured in the preceding head diagnosis mode, and an initial resistance value r
0I of the heat generation resistive element 93R
I at the time of manufacturing.
[0087] Subsequently, at step SP11, the CPU 61 calculates a changing rate A
I of the resistance value r
I of the heat generation resistive element 93R
I measured at this time to the resistance value r
I' of the heat generation resistive element 93R
I measured at the preceding time as represented by the following expression (2):

[0088] Subsequently, the CPU 61 proceeds to step SP12, where it determines whether or not
the difference between the changing rate A
I and a changing rate A
I' which is calculated in the preceding head diagnosis mode is equal to or less than
a predetermined value. If a negative result is returned, this means that it is highly
likely that the heat generation resistive element 93R
I falls into an abnormal electrification state. The CPU 61 proceeds to step SP13 illustrated
in Fig. 13, where it judges whether the changing rate A
I exceeds a predetermined value which is set as an abnormal changing rate.
[0089] If a negative result is returned at step SP13, this means that the difference between
the changing rate A
I and the previously calculated changing rate A
I' is equal to or more than the predetermined value and equal to or less than the predetermined
value above which an abnormal changing rate is identified. At this point, the CPU
61 proceeds to step SP14, where it sets a flag representative of a warning (hereinafter
referred to as the "warning flag") in the flash memory 81 in order to register that
the heat generation resistive element 93R
I is less likely to fall into an abnormal electrification state at this time.
[0090] Subsequently, the CPU 61 proceeds to step SP15, where it judges whether or not a
warning flag has been set in the flash memory 81 for the heat generation resistive
element 93R
I in the preceding head diagnosis mode.
[0091] If an affirmative result is returned at step SP15, this means that the heat generation
resistive element 93R
I has been likely to fall into an abnormal electrification state not only at the preceding
time but also at the present time. At this point, the CPU 61 proceeds to step SP7,
where it judges in the foregoing manner that the heat generation resistive element
93R
I has been in an abnormal electrification state, and notifies the host computer 60
of this fact.
[0092] On the other hand, if a negative result is returned at step SP15, this means that
the heat generation resistive element 93R
I could exhibit for the first time an abnormal electrification state in the current
head diagnosis mode, in which case the CPU 61 proceeds to step SP9.
[0093] Turning back to step SP12 illustrated in Fig. 12, if an affirmative result is returned,
this means that the difference between the changing rate A
I and a changing rate A
I' which is calculated in the preceding head diagnosis mode of the heat generation
resistive element 93 R
I is equal to or less than the predetermined value, and accordingly the heat generation
resistive element 93R
I exhibits a normal electrification state, in which case the CPU 61 proceeds to step
SP16 (Fig. 13), where it overwrites the current resistance value r
I and the changing rate A
I of the heat generation resistive element 93R
I in the flash memory 81.
[0094] Subsequently, even if the changing rate A
I is within the predetermined range, the thermal head 23 is likely to fall into a fault
if the resistance value r
I of the heat generation resistive element 93R
I takes a value out of the predetermined range with respect to the initial resistance
r
0I. Thus, the CPU 61 proceeds to step SP17, where it judges whether or not the difference
between the resistance value r
I and the initial resistance value r
0I is equal to or less than a predetermined value.
[0095] If a negative result is returned at step SP17, the CPU 61 proceeds to step SP7, where
it notifies the host computer 60 of the fact that the heat generation resistive element
93R
I exhibits an abnormal electrification state, similarly to the above. As a result,
the host computer 60, upon receipt of the notification from the CPU 61, displays on
the display screen of the error display part 82 that the thermal head 23 is faulty
or likely to fall into a fault.
[0096] On the other hand, if an affirmative result is returned at step SP17, this means
that the heat generation resistive element 93R
I is in a normal electrification state, in which case the CPU 61 proceeds to step SP9,
where it judges whether the heat generation resistive element 93R
I is the last electrified heat generation resistive element 93R
N.
[0097] If an affirmative result is returned at step SP9, the CPU 61 judges that the diagnosis
has been completed for all the heat generation resistive elements 93R
1 to 93R
N as to whether or not they exhibit an abnormal electrification state, and then proceeds
immediately to step SP18 to terminate the head diagnosis processing procedure RT1.
[0098] On the other hand, if a negative result is returned at step SP9, the CPU 61 again
returns to step SP3, where it executes the processing from step SP3 to step SP17 for
the next electrified heat generation resistive element 93R
I+1 as described above, and repeats this processing until an affirmative result is returned
at step SP9.
(5) Operation and Effect of Embodiment
[0099] In the configuration described above, in the color image printing part 20 in the
card printer 10, the heat generation resistive elements 93R
1 to 93R
N in the plurality of heat generators 23H
1 to 23H
N arranged on the surface of the thermal head 23 are sequentially electrified one by
one, and the resistance value of the heat generation resistive elements 93R
1 to 93R
N is measured respectively to determine whether or not each of the heat generation
resistive elements 93R
I (1≦I≦N) is open or short-circuited based on the resistance value r
I thereof during the head diagnosis mode.
[0100] If the respective heat generation resistive elements 93R
I are not open or short-circuited, then the changing rate A
I of the heat generation resistive element 93R
I is calculated on the basis of the resistance value r
I' of the heat generation resistive element 93R
I measured at the preceding time and the resistance value r
I corresponding thereto measured at the current time. It can be determined on the basis
of each changing rate A
I whether or not the associated heat generation resistive element 93R
I is currently in a normal electrification state or is likely to suffer a fault in
future, before actually entering a printing stage.
[0101] In this event, even if each heat generation resistive element 93R
I is determined to be normal at present, it can be judged whether or not the thermal
head 23 is faulty or is likely to fall into a fault in accordance of the difference
between the changing rate A
I of the heat generation resistive element R
I and the previously calculated changing rate A
I' of the heat generation resistive element 93R
I' corresponding thereto.
[0102] When it is determined as above that the thermal head 23 is faulty or is likely to
fall into a fault, this fact is displayed on the error display unit 82, thereby allowing
the operator to readily and visually confirm the condition of the thermal head 23
before entering a printing stage.
[0103] Even when some heat generation resistive elements 93R
X (X is an arbitrary number) of the plurality of heat generation resistive elements
93R
1 to 93R
N are opened, the heat generation resistive elements 93R
X are treated as normal if the heat generation resistive elements 93R
X are not actually heat generation resistive elements which correspond to an image
printing area based on image printing data D
P within an image to be printed, because they do not affect the contents printed on
a card material 13. In this way, when the heat generation resistive elements 93R
X only are opened among the plurality of heat generation resistive elements 93R
1 to 93R
N, the thermal head 23 need not be replaced with a new one, thereby making it possible
to further improve the use efficiency of the thermal head 23.
[0104] According to the foregoing configuration, in the color image printing part 20 of
the card printer 10, the heat generation resistive elements 93R
1 to 93R
N within the plurality of heat generators 23H
1 to 23H
N arranged on the surface of the thermal head 23 are sequentially electrified one by
one before starting a printing operation or after ending a printing operation. Then,
the changing rate A
I is calculated on the basis of the previously measured resistance value r
I' of each heat generation resistive element 93R
I (1≦I≦N) and the corresponding resistance value r
I measured at the current time. Then, a electrification state of the corresponding
heat generation resistive element 93R
I is determined on the based on the changing rate A
I, thereby making it possible to previously judge the condition of the thermal head
23 before entering an actual printing stage. Consequently, printing errors can be
efficiently prevented.
(5) Other Embodiments
[0105] In the foregoing embodiment, when a heat generation resistive element 93R
I exhibits an abnormal electrification state, the CPU 61 judges the host computer 60
of this fact as the predetermined error processing, so that the host computer 60 forces
the error display part 82 to display on its display screen that the thermal head 23
is faulty or is likely to fall into a fault. The present invention is not limited
thereto. Alternatively, when a heat generation resistive element 93R
I exhibits an abnormal electrification state, the CPU 61 can bring the color image
printing part 20 into a printing stop state instead of or in addition to notifying
the host computer 60 of the fact. In this case, even if the color image printing part
20 is switched to a printing mode, it is possible to obviate printing errors on a
card material 13 since the color image printing part 20 is in the printing stop state.
[0106] Also, in the foregoing embodiment, when a certain heat generation resistive element
93R
X (X is an arbitrary number) among the plurality of heat generation resistive elements
93R
1 to 93R
N is opened, the CPU 61 sends a printing reference signal S2 to the host computer 60
so that the host computer 60 judges whether or not the heat generation resistive element
93R
X is actually a heat generation resistive element which corresponds to an image printing
area based on image printing data D
P within an image to be printed. The present invention, however, is not limited thereto.
Alternatively, the color image printing part 20 illustrated in Fig. 7 can be provided
therein with a frame memory (not shown) for storing an image based on the image printing
data D
P so that the CPU 61 makes the above-mentioned determination based on the image printing
data D
P read from the frame memory, without intervention of the host computer 60.
[0107] Further, in the foregoing embodiment, when the resistance value of each heat generation
resistive element 93R
1 to 93R
N are measured, the CPU 61 uses a predetermined conversion table to retrieve the resistance
value of each heat generation resistive element 93R
I (1≦I≦N) corresponding to differential voltage data D
VS supplied from the head diagnosis part 80. The present invention, however, is not
limited thereto. Alternatively, the CPU 61 does inverse calculating differential voltage
data D
VS outputted from the head diagnosis part 30 to derive the resistance value of each
heat generation resistive element 93R
I. In essence, a wide variety of other configurations can be applied as measuring means
as long as it can measure the resistance value of each electrified heat generation
resistive element 93R
I.
[0108] Further, in the foregoing embodiment, the CPU 61, serving as calculation means, calculates
the change rate A
I for the resistance value of each heat generation resistive element 93RI based on
the resistance value r
I' of each heat generation resistive element 93R
I previously measured in the head diagnosis part 80 and the resistance value r
I of each heat generation resistive element 93R
I measured at this time. The present invention, however, is not limited thereto. Alternatively,
a wide variety of other configurations can be applied as the calculating means.
[0109] Further, in the foregoing embodiment, the CPU 61, serving as diagnosis means, relies
on the change rate A
I for the resistance value r
I of each heat generation resistive element 93R
I to jugde a electrification state of the corresponding heat generation resistive element
93R
I, and with the result of the judgement judges the condition of the thermal head 23
in accordance. The present invention, however, is not limited thereto. In essence,
the host computer 60 can be used as the diagnosis means, or a wide variety of other
configurations can be applied as the diagnosis means, as long as it can readily judge,
before actually entering a printing stage, whether or not each heat generation resistive
element 93RI is currently in a normal electrification state, or whether or not a fault
is currently occurring, or whether or not a fault is likely to occur in future.
[0110] Further, in the foregoing embodiment, the flash memory 81 is used as storage means
for storing the resistance value r
I of each heat generation resistive element 93R
I measured in the head diagnosis part 80. The present invention, however, is not limited
thereto, but a variety of configurations can be applied including, for example, electrically
erasable programmable read only memory (EEPROM), static random access memory (static
RAM), or the like.
[0111] Further, while in the foregoing embodiment, the card material 13 in accordance with
the ISO standard is used as a printing medium, the present invention is not limited
thereto. Alternatively, a card material in accordance with Japan Industrial Standard
(JIS) can be used. Further alternatively, the present invention can also be applied
to a variety of card materials, which do not have an IC card and/or magnetic stripes.
[0112] According to the present invention as described above, a head diagnosis apparatus
for diagnosing the condition of a thermal head comprises: measuring means for measuring
respectively the resistance value of a plurality of heat generation resistive elements
arranged on a head surface of the thermal head; storage means for storing the resistance
value of each of the heat generation resistive elements measured by the measuring
means; calculating means for calculating a change amount of the resistance value of
each heat generation resistive element based on the resistance value of each heat
generation resistive element measured in the past, stored in the storage means, and
the resistance value of each heat generation resistive element measured by the measuring
means; and diagnosis means for judging a electrification state of each heat generation
resistive elements based on the calculation result of the calculating means to diagnose
the condition of the thermal head in accordance with the judgement result; thereby
making it possible to diagnose the condition of the thermal head before entering a
printing stage. Consequently, it is possible to realize a head diagnosis apparatus
which is capable of efficiently preventing printing errors.
[0113] Also, in the present invention, a thermal head diagnosis method for diagnosing the
condition of a thermal head first measures respectively the resistance value of a
plurality of heat generation resistive elements arranged on a head surface of the
thermal head, and then calculates a change amount of the resistance value of each
heat generation resistive element based on the resistance value of each heat generation
resistive element measured in the past, and the resistance value of each heat generation
resistive elements measured at the current time to determine a electrification state
of each heat generation resistive element based on the calculation result for diagnosing
the condition of the thermal head in accordance with the judgement result, thereby
making it possible to diagnose the condition of the thermal head before entering a
printing stage. Consequently, it is possible to realize a head diagnosis method which
is capable of efficiently preventing printing errors.
[0114] While there has been described in connection with the preferred embodiments of the
invention, it will be obvious to those skilled in the art that various changes and
modifications may be aimed, therefore, to cover in the appended claims all such changes
and modifications as fall within the true spirit and scope of the invention.