Automated banding defect analysis and repair for document processing systems

• US 6,862,414 B2
• Filed: 01/30/2002
• Issued: 03/01/2005
• Est. Priority Date: 01/30/2002
• Status: Expired due to Term

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Minhas, Raj, Rockwell, Ronald M., Jackson, Eric, Sampath, Meera, Rasmussen, D. Rene, Godambe, Ashok V.
• Primary Examiner(s): Beatty, Robert
• Application Number:
  US10/060,651
• Publication Number:
  US 20030142985A1
• Time in Patent Office: 1,126 Days
• Field of Search: 399/9, 399/15, 399/42, 399/49, 399/72, 382/112, 358/406, 358/462, 358/300, 358/302
• US Class Current: 399/15
• CPC Class Codes: G03G 15/5062 by measuring the characteristics of an image on the copy material
• CPC Class Codes: G03G 15/5079 for maintenance
• CPC Class Codes: G03G 15/55 Self-diagnostics; Malfunction or lifetime display

Abstract

Using a system of computer modules operatively associated with a document processing machine, banding defect analysis is accomplished by analyzing specific test patterns via image processing. The banding defects are characterized in terms of quantitative parameters based on an analysis of the banding defect. Key features are extracted from the banding defect parameters. The key features are analyzed in a diagnostic engine, to determine the possible source of the defect. The identified source is correlated to a recommended repair service procedure. The diagnostic process may be augmented by also including machine data in the analysis.

Claims

1. A diagnostic system for diagnosing the cause of banding defects in a document processing system comprising:

a scanner far generating image data by digitizing hardcopy samples obtained by printing or copying a test pattern on said document processing system;

an image quality analysis module adapted to receive said image data and to detect the presence of banding defects, said image quality analysis module further analyzing said image data relating to a detected banding defect to obtain quantified parameters of said banding defect and extradting key features from said quantified parameters;

a diagnostic engine adapted to receive and analyze said key features, said diagnostic engine further identifying one or more malfunctions which are possible causes of said defect based on said analysis of said key features, through iterative cycles of analysis based on one or more test patterns;

a repair planning module adapted to receive the malfunctions identified by said diagnostic engine and select, from a plurality of service procedures1 one or more of said procedures which are likely to correct said malfunction;

a memory module for storing data and algorithms relating to said diagnostic system;

a diagnostic control module adapted to control and coordinate the operation of said modules.

2. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said scanner is a component of the document processing system.

3. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said repair planning module further causes said selected service procedure to automatically be performed in said document control system.

4. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said repair planning module further causes said selected service procedure to be presented to a user of said document processing system through a user interface, wherein said user may cause said selected service procedure to be performed in said document control system.

5. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said image quality analysis module applies one or more methods selected from the group consisting of fourier analysis, filtering, and visual perception analysis to said image data to generate said banding defect analysis output.

6. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 4, wherein said image quality analysis module further applies a series of algorithms which use said banding defect parameters and predetermined threshold values of such parameters to extract said key features from said banding defect parameters.

7. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said diagnostic engine applies reasoning techniques to said key features to identify causation of said defects.

8. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said diagnostic engine calculates the probability of causation for a plurality of malfunctions in said system for said key features to identify one or more malfunctions which are possible causes of said defect.

9. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 8 wherein said diagnostic engine applies a bayesian analysis to said key features to calculate said probabilities of causation.

11. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said diagnostic system memory has data stored therein relating to banding defects, and a series of algorithms, said algorithms generating said key features from said banding defect quantified parameters using threshold values for such parameters and device specific specifications.

12. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said memory stores data relating to causes of banding defects correlated to banding defect features indicative of said causes, for use by said diagnostic engine in the identification of said one or more malfunctions.

14. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, further comprising a machine data module for compiling machine operation data and performance data for analysis by said diagnostic engine to augment the analysis based on said banding defect analysis.

15. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 14, wherein said machine data module further comprises:

a machine interface for connection of said machine data module to at least one component of said document processing system to send and receive signals to and from said document processing system relating to performance of said system;

a machine test module for invoking/executing predetermined performance tests or diagnostic tests on said document processing system to generate at least a portion of said machine data;

a machine data processor for compiling and extracting said machine data features and sending said data to said diagnostic engine.

16. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 15, wherein said machine test module further stores and runs said performance tests or diagnostic tests on said document processing system.

17. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 15, wherein said machine data processor module applies a series of algorithms which utilize predetermined parameters to generate machine data features.

18. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 17, wherein said algorithms are based on statistical analysis and data mining techniques.

19. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 17, wherein said diagnostic system memory stores data relating to causes of banding defects correlated to machine data features indicative of said causes, for use by said diagnostic engine in the identification of said one or more malfunctions.

20. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 15, wherein said diagnostic system memory has data stored therein relating to machine data, and a series of algorithms for generating features from said machine data, where said algorithms utilize a set of predetermined parameters.

23. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said image quality analysis module further comprises:

a banding defect analyzer for analyzing said image data and calculating said banding defect quantified parameters; and

a feature extraction processor for executing a series of algorithms comparing said parameter values of said banding defect analysis to predetermined thresholds and device specific specifications to identify said key features of said banding defect.

24. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 1, wherein said diagnostic engine selects said malfunctions by comparing said probability of causation for a malfunction to a predetermined certainty threshold.

10. A diagnostic system for diagnosing the cause of banding defects in a document processing system comprising:

a scanner for generating image data by digitizing hardcopy samples obtained by printing or copying a test pattern on said document processing system

an image quality analysis module adapted to receive said image data and to detect the presence of banding defects, said image quality analysis module further analyzing said image data relating to a detected banding defect to obtain quantified parameters of said banding defect and extracting key features from said quantified parameters;

a diagnostic engine adapted to receive and analyze said key features, said diagnostic engine further identifying one or more malfunctions which are possible causes of said defect based on said analysis of said key features;

a repair planning module adapted to receive the malfunctions identified by said diagnostic engine and select, from a plurality of service procedures, one or more of said procedures which are likely to correct said malfunction;

a memory module for storing data and algorithms relating to said diagnostic system;

a diagnostic control module adapted to control and coordinate the operation of said modules; and

a test pattern selection module that determines the next test pattern to be printed or copied and then scanned and the next set of features to be evaluated during successive diagnostic process cycles.

13. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 10, wherein said memory stores data relating to causes of banding defects correlated to test patterns capable of providing banding defect features indicative of said causes, for use by said test pattern selection module in the choice of the test pattern to be scanned.

21. A diagnostic system for diagnosing the cause of banding defects in a document processing system comprising:

a scanner for generating image data by digitizing hardcopy samples obtained by printing or copying a test pattern on said document processing system

an image quality analysis module adapted to receive said image data and to detect the presence of banding defects, said image quality analysis module further analyzing said image data relating to a detected banding defect to obtain quantified parameters of said banding defect and extracting key features from said quantified parameters;

a diagnostic engine adapted to receive and analyze said key features, said diagnostic engine further identifying one or more malfunctions which are possible causes of said defect based on said analysis of said key features;

a repair planning module adapted to receive the malfunctions identified by said diagnostic engine and select, from a plurality of service procedures, one or more of said procedures which are likely to correct said malfunction;

a memory module for storing data and algorithms relating to said diagnostic system;

a diagnostic control module adapted to control and coordinate the operation of said modules;

a machine data module for compiling machine operation data and performance data for analysis by said diagnostic engine to augment the analysis based on said banding defect analysis; and

a test selection module that determines the next test pattern to be scanned or the next machine test to be run and the next set of features to be evaluated during successive diagnostic process cycles.

22. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 21, wherein said memory stores data relating to causes of banding defects correlated to tests capable of isolating said causes, for use by said test selection module in the choice of the test to be performed.

25. A diagnostic system for diagnosing the cause of banding defects in a document processing system comprising:

a scanner for generating image data by digitizing hardcopy samples obtained by printing or copying a test pattern on said document processing system

an image quality analysis module adapted to receive said image data and to detect the presence of banding defects, said image quality analysis module further analyzing said image data relating to a detected banding defect to obtain quantified parameters of said banding defect and extracting key features from said quantified parameters;

a diagnostic engine adapted to receive and analyze said key features, said diagnostic engine further identifying one or more malfunctions which are possible causes of said defect based on said analysis of said key features;

a repair planning module adapted to receive the malfunctions identified by said diagnostic engine and select, from a plurality of service procedures, one or more of said procedures which are likely to correct said malfunction;

a memory module for storing data and algorithms relating to said diagnostic system;

a diagnostic control module adapted to control and coordinate the operation of said modules; and

a user interface module adapted to receive information from the user that characterizes the banding defects observed by the user.

26. A system for diagnosing the cause of banding defects in a document processing system, as described in claim 25, further comprising a preprocessor for compiling said user input data and sending said data to said diagnostic engine.

27. A method for diagnosing the cause of banding defects in a document processing system comprising the steps of:

producing a hardcopy print or copy sample of an original hardcopy or digital test pattern on said document processing system;

generating digital image data from said hardcopy print or copy sample;

analyzing said image data to detect the presence of banding defects;

analyzing the image data to obtain quantified parameters characterizing said banding defect;

extracting key features from said banding defect quantified parameters;

identifying one or more malfunctions which are possible causes of said defect by analysis of said key features through iterative cycles of analysis based on one or more test patterns;

selecting, from a plurality of service procedures, one or more of said procedures which are likely to correct said identified one or more malfunctions.

28. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, further comprising the step of causing said selected service procedure to be automatically performed in said document control system.

29. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, further comprising the step of presenting to a user said selected service procedure to be performed in said document. control system.

30. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein said step of generating banding defect quantified parameters is accomplished by applying one or more methods selected from the group consisting of a fourier analysis, band pass filtering and visual perception analysis to said image data.

31. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein the step of extracting key features comprises applying a series of algorithms on said quantified parameters, wherein said algorithms use predetermined threshold values for said parameters and device specific specifications.

32. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein said step of identifying malfunctions comprises applying reasoning techniques on said key features.

33. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein said step of identifying malfunctions comprises calculating the probability of causation of a plurality of malfunctions in said system for said key features.

34. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein said step of calculating said probabilities of causation comprises applying a bayesian analysis to said key features.

35. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein said step of extracting key features further comprises the steps of:

storing data relating to banding defects, comprising predetermined threshold values and device specific specifications; and

applying a series of algorithms to said banding defect quantified parameters which utilize said stored data to extract said key features.

36. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, further comprising the step of storing data relating to causes of banding defects correlated to banding defect features indicative of said causes, for use by said diagnostic engine in the identification of said one or more malfunctions.

37. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, further comprising the step of compiling machine data, for analysis by said diagnostic engine to augment the analysis based on said banding defect analysis output.

38. A method for diagnosing the cause of banding defects in a document processing system, as described in claim. 37, further comprising the steps of:

sending and receiving signals to and from said document processing system relating to performance of said system;

running predetermined performance or diagnostic tests on said document processing system to generate at least a portion of said machine data;

analyzing said machine data using a series of algorithms to extract machine data features; and

compiling said machine data features and sending said features to said diagnostic engine.

39. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, wherein said step of selecting probable malfunctions comprises the step of comparing said probability of causation for a malfunction to a predetermined certainty threshold.

40. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 37, further comprising the step of storing said performance or diagnostic tests.

41. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 37, further comprising the said step of analyzing said machine data using a series of algorithms that utilize predetermined parameters to generate machine data features.

42. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 37, wherein said step of generating machine data uses algorithms based on statistical analysis and data mining techniques.

43. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, further, comprising the said step of selecting a series of tests to be performed correlated to features to be evaluated.

44. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 42, further comprising the said step of storing data relating to causes of banding defects correlated to tests capable of providing banding defect or machine data features indicative of said causes, for use in the choice of the tests to be performed.

49. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 27, further comprising the step of storing data relating to causes of banding defects correlated to machine data features indicative of said causes, for use by said diagnostic engine in the identification of said one or more malfunctions.

45. A method for diagnosing the cause of banding defects in a document processing system comprising the steps of:

producing a hardcopy print or copy sample of an original hardcopy or digital test pattern on said document processing system;

generating digital image data from said hardcopy print or copy sample;

analyzing said image data to detect the presence of banding defects;

analyzing the image data to obtain quantified parameters. characterizing said banding defect;

extracting key features from said banding defect quantified parameters;

identifying one or more malfunctions which are possible causes of said defect by analysis of said key features;

selecting, from a plurality of service procedures, one or more of said procedures which are likely to correct said identified one or more malfunctions; and

entering data through a user interface characterizing the banding defects observed by the user.

46. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 45, wherein the said step of entering data through the user interface further includes the step of preprocessing said data and considering said user entered data in the analysis of said image data.

47. A method for diagnosing the cause of banding defects in a document processing system comprising the steps of:

producing a hardcopy print or copy sample of an original hardcopy or digital test pattern on said document processing system;

generating digital image data from said hardcopy print- or copy sample;

analyzing said image data to detect the presence of banding defects;

analyzing the image data to obtain quantified parameters characterizing said banding defect;

extracting key features from said banding defect quantified parameters;

identifying one or more malfunctions which are possible causes of said defect by analysis of said key features;

selecting, from a plurality of service procedures, one or more of said procedures which are likely to correct said identified one or more malfunctions; and

determining the next test pattern to be printed or copied and then scanned and the next set of features to be evaluated during successive diagnostic process cycles.

48. A method for diagnosing the cause of banding defects in a document processing system, as described in claim 47, further comprising the step of storing data relating to causes of banding defects, correlated to test patterns capable of providing banding defect features indicative of said causes, for use in the choice of the test pattern to be scanned.