A recycled toner cartridge anti-leakage toner multiplexing process and system based on residual powder compatibility determination and multiplexing level routing

Abstract

The application discloses a recycled selenium drum powder leakage prevention and reuse process and system based on residual powder compatibility determination and reuse level routing. High page yield office selenium drum models are identified, and powder bin shells, waste powder bin shells and driving interfaces are checked; the particle size, moisture content, rest angle and mass ratio difference of residual powder and target new carbon powder are detected, and a compatibility index is calculated K ; the remaining life of a key old part is detected L i , and a life score is calculated R . After structure checking, the compatibility threshold, life threshold and minimum component life threshold pre-calibrated and solidified in the model process library are called, and R and L i conditions are input K to a joint determination matrix K-R , and material recycling, part utilization, powder addition after part replacement or powder addition without part replacement are output. Recalculation R′ and L i′ is performed after part replacement; when the access conditions are met, the powder cleaning degree is determined according to K , and the powder is added quantitatively, and the sealing performance and printing quality are checked.

Description

Technical Field

[0001] This invention relates to the field of laser printer toner cartridge regeneration technology, specifically to a toner cartridge anti-leakage reuse process and system based on residual toner compatibility determination and reuse level routing. Background Technology

[0002] High-output office laser printers are typically used for bulk printing, and their toner cartridges have a high rated print volume. When the toner in these cartridges is depleted, the casing, imaging, and transmission components often still have remaining lifespan; replacing the entire cartridge would increase procurement costs and waste usable parts.

[0003] Current recycling processes mainly rely on manual assessments to determine whether powder can be added, or on a uniform powder removal and parts replacement approach. The former lacks recalculation data, while the latter cannot select the treatment intensity based on residual powder compatibility and the actual condition of each used part.

[0004] Current methods cannot integrate residual powder status and the lifespan of old parts into the same judgment process, which can easily lead to situations where old parts are not yet ready to be refilled with powder, or where residual powder that could be retained is completely removed. Summary of the Invention

[0005] This invention adopts K - R Joint judgment. Structural checks are a prerequisite for matrix operation; if irreparable structural defects exist, the entire drum reuse process is halted; if no structural veto is triggered, the matrix will... R and L i condition, K The conditions are listed separately, and the processing path is directly given by the matrix row that simultaneously satisfies both types of conditions. The model process library is pre-set. R 1. R 2. R 3. L min , K 1 and K 2. Recalculation is required when partial parts need to be replaced. R 'and L i′ After the review is passed, proceed according to the corresponding procedures. K Conditions are applied to clean and add powder.

[0006] The R 1. R 2. R 3. L min , K 1 and KBoth parameters are pre-calibrated and fixed in the model process library based on the toner cartridge model structure, nominal print volume, target reuse print volume, critical old component scrapping threshold, target new toner, and quality acceptance conditions. The same set of thresholds should be used for the same model when using the same target new toner, target reuse print volume, and quality acceptance conditions, and should not be adjusted temporarily based on the test results of a single toner cartridge.

[0007] The first objective of this invention is to provide a leak-proof toner cartridge reuse process based on residual toner compatibility determination and reuse level routing, comprising: Identify the model of the recycled toner cartridge and establish a set of key used parts I(M) for that model. Inspect the toner cartridge housing, waste toner cartridge housing, and drive interface of the recycled toner cartridge for defects that cannot be eliminated by repair or component replacement. Defects include cracks, damage, or deformation. If defects that cannot be eliminated by repair or component replacement are present, the entire cartridge must not be reused. When whole-drum reuse is not prohibited, residual toner samples are collected, and the differences between the residual toner and the target new toner compatible with this model in terms of particle size, moisture content, angle of repose, and mass-to-charge ratio are detected. The residual toner compatibility index is then calculated. K ; The remaining life percentage of each critical used component within the detection set I(M) L i The weights of the critical used parts actually existing in this model are normalized to a sum of 1, and a lifespan score is calculated. R ; Build K - R Joint judgment matrix, setting lifespan score R and percentage of remaining lifespan L i Compatibility index with residual powder K The processing results are listed in columns, with each matrix row consisting of a lifespan score. R and percentage of remaining lifespan L i With a residual powder compatibility index K Commonly defined; the processing results include material recycling, dismantling and reuse, partial replacement with powder addition or no replacement with powder addition; Preset the first lifespan threshold R 1. Second lifetime threshold R 2. Third lifespan threshold R 3. Minimum component lifespan threshold L min First compatibility threshold K 1 and second compatibility threshold K 2, where 0 < R 1 < R 2< R3≤100%, 0< L min ≤100%, 0 < K 1 < K 2; According to lifespan rating R Percentage of remaining useful life of each critical old component L i Compatibility index with residual powder K ,based on K - R The joint judgment matrix outputs the processing result, where: R < R Material recycling begins at 1 o'clock; R ≥ R 1 and exists L i < L min Furthermore, if critical old parts cannot be replaced individually, they are used for disassembly and reuse; if no such critical old parts cannot be replaced individually, R 1≤ R < R 2. Disassemble and reuse parts. R 2≤ R < R 3 or R ≥ R 3 But it exists L i < L min When key old parts can be replaced individually, partial replacement conditions are entered. R ≥ R 3 and all L i ≥ L min When entering the condition of adding powder without changing parts; K > K 2. K 1 < K ≤ K 2 and K ≤ K 1 corresponds to complete powder removal, partial powder removal, and low-percentage residual powder retention, respectively; Among them, the processing results determine the toner cartridges that are allowed to be refilled, and the residual old toner mass M after cleaning is weighed to determine the mass. res and according to M add =M target M res After replenishing with the target new toner, seal the toner inlet, where M target M represents the target total powder mass specified in the model process library. add The actual mass of the new toner added; After adding toner, a sealing check and a print quality check are performed, and the output is either qualified, reworked, or returned for reuse as a whole drum.

[0008] In one embodiment, the residual powder compatibility index K Used to determine the degree of powder removal: K ≤ K At time 1, a low proportion of residual powder is retained; K 1 < K ≤ K Partial powder removal is used at 2 o'clock; K > K Complete powder removal is performed at time 2; The low percentage of residual powder retention refers to the amount of residual old powder (M) remaining in the powder hopper and developing area after cleaning visible agglomerated powder and waste powder. res Greater than the target total powder mass M of the model target 1% and not exceeding M target 5%; The term "partial powder cleaning" refers to removing visible residual powder from the powder container and developing area, ensuring that 0 < M. res ≤M target 1%, and has not yet met the criteria for complete powder removal; The complete toner cleaning refers to emptying the toner hopper, developing area, and waste toner holding area of ​​the old toner and cleaning the toner supply channel, so that M res The weighing resolution is 0 and there is no visible residual powder in the above area; M target M represents the target total powder mass specified in the model process library. res It is determined by the difference between the weighing value after cleaning and the baseline mass of the empty chamber of the same model.

[0009] In one embodiment, the critical legacy parts set I(M) is determined from general candidate parts and model-specific parts; The general candidate components include the photosensitive imaging element, developing element, charging element, toner feeding element, toner dispensing control element, cleaning element, sealing element, and waste toner container that are actually present in this model. The model-specific components are determined by the model process library based on the actual structure of the model, and added to set I(M) after their actual existence is confirmed; If a candidate component does not exist in this model, it is not set. L i And prevent it from participating with a zero value. R Calculation; For the basic weights in set I(M) Normalization is performed to obtain , and according to Calculate lifespan score R ; For any critical used part in the critical used parts set I(M), obtain the current detection value of the degradation index corresponding to the critical used part, the benchmark value of the new part of the same model, and the scrapping threshold; for degradation indices that continuously increase or decrease with the degree of degradation, according to the direction of change of the degradation index, with the new part benchmark value corresponding to 100% and the scrapping threshold corresponding to 0%, the current detection value is linearly converted into the remaining life percentage corresponding to the degradation index; when the current detection value reaches or exceeds the new part benchmark value, it is taken as 100%, and when it reaches or exceeds the scrapping threshold, it is taken as 0%. When a critical used part has more than two degradation indicators, the remaining useful life percentage corresponding to each degradation indicator is determined separately, and the minimum value among them is taken as the remaining useful life percentage of the critical used part. L i For structural indicators such as cracks, fractures, or other defects that are judged as acceptable or unacceptable, the percentage of remaining service life is taken as 100% when acceptable and 0% when unacceptable. Key old parts that can be replaced individually L i Below L min At that time, the critical old part is marked as a replacement part, and the entire drum does not trigger a structural veto and life score is calculated. R When the conditions for partial replacement are met, the partial replacement process begins; critical old parts that cannot be replaced individually... L i Below L min At this time, stop adding powder to the entire drum and proceed with disassembly and reuse; L i Below L min The structure itself is not a rejection condition for the entire drum structure. The rejection is triggered by defects in the powder hopper housing, waste powder hopper housing, or drive interface that cannot be eliminated by repair or component replacement.

[0010] In one embodiment, the first lifetime threshold R 1 is 30%, the second lifespan threshold. R 2 is 60%, the third lifespan threshold. R 3 is 85%, the minimum component lifespan threshold. L min The first compatibility threshold is 60%. K 1 is 0.15, the second compatibility threshold. K 2 is 0.40; When the powder hopper housing, waste powder hopper housing, or drive interface has irreparable cracks, damage, or deformation, it is not considered. K and R The value of the drum is used to prohibit the reuse of the entire drum; There are no irreparable structural defects. R ≥R 3 and all L i ≥ L min At that time, it was a candidate for adding powder directly without changing parts; There are no irreparable structural defects, and R 2≤ R < R 3, or R ≥ R 3 But it exists L i < L min When a critical old part can be replaced individually, it is a candidate for adding powder after replacement. R 1≤ R < R 2, or R ≥ R 2 and exist L i < L min Furthermore, if critical old parts that cannot be replaced individually, or if the powder filling access conditions are still not met after partial replacement, they will be disassembled and reused. R < R At 1 o'clock, the material recycling process begins.

[0011] In one embodiment, construct KR When using a joint judgment matrix, set the following respectively: R and L i condition column, K The condition column and the processing result column specifically include: (1) If there are irreparable structural defects before entering the matrix, it is not considered. K , R and L i The value of [value] indicates that the reuse of the entire drum should be stopped and the process should begin material recycling. (2) The above R and L i The condition column includes R < R 1, R 1≤ R < R 2, R ≥ R 2 and exist L i < L min And critical old parts that cannot be replaced individually. R 2≤ R <R 3 or R ≥ R 3 But it exists L i < L min Key old parts that can be replaced individually, and R ≥ R 3 and all L i ≥ L min ; (3) The above K The condition column includes K > K 2. K 1 < K ≤ K 2 and K ≤ K 1. These correspond to completely removing powder, partially removing powder, and retaining a low percentage of residual powder, respectively. (4) R < R 1 and any K Output material recovery when conditions are combined; R 1≤ R < R 2, or R ≥ R 2 and exist L i < L min When a critical old part cannot be replaced individually, it is related to any K All combinations of conditions output the components for reuse. R ≥ R 3 and all L i ≥ L min At that time, according to the corresponding K Conditional output options include: complete powder cleaning and refilling without changing parts; partial powder cleaning and refilling without changing parts; or low-percentage residual powder retention and refilling without changing parts. (5) When it falls under the condition of partial replacement, if there are L i < L min If critical old parts cannot be replaced individually, then stop adding toner to the entire drum and proceed with disassembly and reuse; otherwise, follow the procedures outlined below. L i Select the key old parts that can be replaced individually in ascending order of their quality, and replace them first. L i < L min The key old parts will be replaced as needed. R 'achieveR 3. Required key old parts, and recalculation. R 'and L i′ ; R ′≥ R 3 and all L i′ ≥ L min At that time, according to the corresponding K If conditions are met, perform powder cleaning and powder addition; otherwise, proceed with disassembly and utilization.

[0012] In one embodiment, when replacing a part partially, if there are L i Below L min For critical old parts that cannot be replaced individually, they are then disassembled and reused; for critical old parts that can be replaced individually, they are handled according to... L i Select in ascending order, replacing first. L i Below L min The key old parts will be replaced as needed. R 'achieve R 3. Required key spare parts; The replaced component uses the test value after replacement. L i′ The original parts were not replaced. L i Or re-detect the value; each L i′ Recalculate using the normalized weights of the model set I(M). R ′; R ′≥ R 3 and all L i′ ≥ L min At that time, according to K Adding powder is allowed after the corresponding degree of powder removal treatment; R ′< R 3 or still exists L i′ < L min At this time, stop adding powder to the drum and proceed with disassembly and reuse.

[0013] In one embodiment, the mass M of residual old toner after cleaning is determined by weighing the toner cartridge that allows for toner refilling. res and according to M add =M target Mres Replenish target new toner, of which M target M represents the target total powder mass specified in the model process library. add The actual quality of the new toner added; after completing the quantitative toner addition, seal the original toner inlet or the process toner inlet; After adding toner, at least check the sealing of the toner filling port and the print quality. If the sealing or printing quality is not up to standard, it should be repaired. If it is still not up to standard after repair, the whole drum should be removed from the service for reuse.

[0014] In one embodiment, the residual powder compatibility index K The median particle size D of the residual toner and the target new toner 50 The normalized deviations of moisture content, angle of repose, and charge-to-mass ratio are calculated using the following formulas:

[0015] In the formula, each deviation term is a non-negative dimensionless value; the sum of all weights is 1, where the particle size term has a weight of 0.30–0.40, the moisture content term has a weight of 0.20–0.30, and the angle of repose and charge-to-mass ratio terms have weights of 0.15–0.25 respectively. The four weights and the normalized moisture content reference MC corresponding to each toner cartridge model are also provided. norm The model process must be determined and fixed in the model process library before testing, and the same model must not be temporarily adjusted based on the test results.

[0016] In one embodiment, it further includes: The toner cartridge model and the actual component assembly I(M) K , R , R ′、 L i , L i′ The matrix rows used, the degree of toner removal, the replacement items, the amount of toner added, the sealing inspection results, the printing quality results, and the final judgment are written into the traceability database.

[0017] The second objective of this invention is to provide a system for implementing a leak-proof toner cartridge reuse process, comprising a data processing device, a model and process library, a residual toner detection device, a used component life detection device, a sealed negative pressure toner cleaning station, and a quantitative toner addition and inspection station; the residual toner detection device and the used component life detection device are connected to the data processing device, and the data processing device calls preset parameters from the model and process library to perform... K , R or R′ Calculate and output KR Joint judgment result; The model identification and structural inspection module runs on the data processing device and is used to determine the actual component set I(M), call the corresponding model process parameters, and record irreparable structural defects. The residual powder detection module includes a residual powder detection device for obtaining particle size, moisture content, angle of repose, and charge-to-mass ratio detection values, and for transmitting the detection values ​​to a data processing device for calculation. K ; The used component life testing module includes a used component life testing device for obtaining at least one of the following test values: film thickness, resistance, surface roughness, dimensions, or drive torque; and for transmitting the test values ​​to a data processing device and calculating the values. L i as well as R or R′ ; The matrix judgment module, running in the data processing device, is used to determine the matrix after the structural check has passed. R and L i conditional sum K Conditional input KR The joint judgment matrix is ​​used, and processing instructions are output to the closed negative pressure powder cleaning station and the quantitative powder addition and inspection station based on the matrix row that simultaneously meets the two types of conditions. The reuse execution and recording module includes the sealed negative pressure powder cleaning station and the quantitative powder addition and inspection station. It is used to receive processing instructions, perform powder cleaning, partial component replacement, powder addition, sealing inspection or exit the whole drum reuse, and transmit the detection input, judgment basis and processing results back to the data processing device for storage.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention uses structural defects as a prerequisite for rejection, and lists them separately in the same matrix. R and L i conditional sum K The conditions establish a clear correspondence between the assessment of the lifespan of old parts and the assessment of residual powder compatibility. Compared with existing manual assessment methods or uniform powder removal methods, all test inputs, part replacement processes, and processing results can be recorded and recalculated, and only the actual components of different models are evaluated. Attached Figure Description

[0019] Figure 1 This invention provides a process and system flowchart for leak-proof toner cartridge reuse based on residual toner compatibility determination and reuse level routing; Figure 2 Schematic diagram of a closed negative pressure powder cleaning and residual powder sampling station; Figure 3 A simplified structural diagram of a rear-mounted self-locking pressure relief and anti-reverse powder filling valve; Figure 4 This is a schematic diagram of the structure of the quantitative powder addition and leak prevention test station. Detailed Implementation

[0020] The invention will now be described with reference to the accompanying drawings and a calculation example using a toner cartridge. The calculation example is for illustrative purposes. K , R Preset threshold and K - R The method of joint judgment; in actual production, all inputs should be based on the test records of the corresponding model and batch.

[0021] This invention is applicable to high-page-rate office toner cartridges where the toner hopper can be replenished and key used parts can be detected or replaced. After model identification, the actual set of key used parts I(M) for that model is first determined, and then the calculation is performed. K and R .

[0022] K - R In the joint judgment, structural inspection serves as a prerequisite for rejection; after passing the structural inspection, R , L i and K As matrix input, R and L i conditional sum K The conditions are listed separately, and the two types of conditions in the same matrix row jointly determine the reuse processing result.

[0023] R 1. Used to distinguish between material recycling and dismantling for reuse. R 2. Used to distinguish between disassembled parts for reuse and partial replacement candidates. R 3. Used to determine whether the condition for adding toner to the entire drum is met after or without replacing parts. L min Used to exclude situations where the overall life score is qualified but the remaining life of a single critical old part is too low; K 1 represents the upper limit for compatibility allowing for a low percentage of residual powder retention. K 2 represents the upper limit of compatibility that allows for the use of partial powder removal.

[0024] Threshold calibration, R 1. R 2. R 3 and L min The determination is based on the model nominal printing volume, target reuse printing volume, key old and new parts value and scrapping threshold, existing maintenance records and preset quality acceptance conditions; K 1 and K2 is determined according to the residual toner compatibility degree, toner cleaning requirement and existing maintenance records when the target new toner of this model is used. After the calibration is completed, the threshold value is stored in association with the applicable toner cartridge model, target new toner, target reusable printing volume and quality acceptance conditions. The above parameters allow re-calibration when the model, target new toner or quality acceptance conditions change, but shall not be temporarily changed during the judgment process of a single toner cartridge.

[0025] See Figure 1 as shown, the process is executed according to the following steps: Figure 1 The process shown in the figure takes K - R joint judgment as the main line. After completing model identification and structure inspection, calculate respectively K , R and each L i ; when the structure rejection is not triggered, R and L i conditions are input into Table 3 respectively with K conditions. After the result of material recycling or component disassembly and utilization is determined, subsequent toner addition is stopped; if it belongs to the local component replacement condition, toner addition can be carried out only after the component replacement is verified to be qualified; if the condition of toner addition without component replacement is met, toner is directly added after treatment according to the corresponding toner cleaning degree K .

[0026] Figure 1 The marked 30%, 60%, 85%, 0.15 and 0.40 are the preferred thresholds adopted in the following HP 147X calculation example, corresponding to R 1, R 2, R 3, K 1 and K 2; other models call the pre-solidified thresholds in their model process libraries according to the same judgment sequence.

[0027] S1. Identify the model of the recycled toner cartridge, establish the key old part set I(M) that actually exists for this model, and check whether there are defects in the powder bin shell, waste powder bin shell and driving interface of the recycled toner cartridge that cannot be eliminated through repair or component replacement, where the defects include crack, damage or deformation; when there are defects that cannot be eliminated through repair or component replacement, the reuse of the whole toner cartridge is prohibited; S2. When the reuse of the whole toner cartridge is not prohibited, collect a residual toner sample, detect the differences in particle size, moisture content, angle of repose and charge-to-mass ratio between the residual toner and the target new toner adapted to this model, and calculate the residual toner compatibility index K； Specifically, when the structure rejection is not triggered, a representative residual toner sample is collected, the particle size, moisture content, angle of repose and charge-to-mass ratio are detected, and the calculation is performed K ; See Figure 2 As shown, the closed negative pressure dust removal and residual powder sampling station includes a closed dust removal chamber 201, a rotary table fixture 202, an opening or disassembly station 203, a dust suction gun 204, a sampling funnel 205, a cyclone separator 206, a filter assembly 207, a negative pressure fan 208, a sample collection cup 209, a dust collection and recovery bin 210, and an operating door or glove opening 211 on the chamber door. The rotary table fixture 202 and the opening or disassembly station 203 are located inside the closed dust removal chamber 201; the dust suction gun 204 is connected to the cyclone separator 206, the filter assembly 207, and the negative pressure fan 208 in sequence via pipelines; the lower end of the sampling funnel 205 is detachably connected to the sample collection cup 209, and the separated dust enters the dust collection and recovery bin 210.

[0028] When this workstation is in operation, the negative pressure fan 208 creates a negative pressure airflow within the sealed powder cleaning chamber 201 and the powder suction pipe, flowing from the inside of the chamber to the filter assembly 207. The powder-containing airflow drawn in by the powder suction gun 204 first undergoes gas-solid separation through the cyclone separator 206, and then the filter assembly 207 traps the fine powder before exhausting the air, thereby reducing the escape of carbon powder during chamber opening, sampling, and powder cleaning.

[0029] During operation, the recycled toner cartridge is fixed to the rotary table fixture 202. After the cabinet door is closed and the negative pressure fan 208 is running, the toner cartridge is opened through the operating door or glove opening 211 at the opening or disassembly station 203. Residual toner is first collected from different locations in the toner cartridge and the developing area, and then introduced into the sample collection cup 209 through the sampling funnel 205 and sealed for testing. Subsequently, localized toner removal or disassembly inspection can be performed on key used parts. This localized toner removal must not alter the quality state of the residual toner in the toner cartridge used to determine the cleaning path. Complete. K , R and each L i Calculate and by K - R After the joint judgment matrix gives the processing result, the dust suction gun 204 is used to perform low-proportion residual dust retention, partial dust removal or complete dust removal, and the cleaned dust is collected by the dust collection and recovery bin 210.

[0030] The residual powder compatibility index K Used to determine the degree of powder removal: according to K definition K condition: K ≤ K 1 corresponds to a low percentage of residual powder retention. K 1 < K ≤ K 2. Corresponding to the part of the powder, K > K 2 corresponds to complete powder removal; The low percentage of residual powder retention refers to the amount of residual old powder (M) remaining in the powder hopper and developing area after cleaning visible agglomerated powder and waste powder.res Greater than the target total powder mass M of the model target 1% and not exceeding M target 5%; The term "partial powder cleaning" refers to removing visible residual powder from the powder container and developing area, ensuring that 0 < M. res ≤M target 1%, and has not yet met the criteria for complete powder removal; The complete toner cleaning refers to emptying the toner hopper, developing area, and waste toner holding area of ​​the old toner and cleaning the toner supply channel, so that M res The weighing resolution is 0 and there is no visible residual powder in the above area; M target M represents the target total powder mass specified in the model process library. res It is determined by the difference between the weighing value after cleaning and the baseline mass of the empty chamber of the same model.

[0031] Residual powder compatibility index K The calculation is as follows: K The residual powder and the target new toner have a median particle size D. 50 The weighted sum of the normalized deviations in moisture content, angle of repose, and charge-to-mass ratio is 1.

[0032] Residual powder compatibility index K The calculation process: (1) The test items are as follows: Particle size deviation, based on the median residual toner particle size D 50， The residual relative to the median particle size D of the target new toner 50， The new representation of relative deviation; Moisture content deviation is expressed as the absolute difference between the residual moisture content (MCresidual) of the residual toner and the target new moisture content (MCnew) of the target new toner, in percentages (%). : Angle of repose deviation, expressed as the relative deviation of the residual toner angle of repose θresidual relative to the target new toner angle of repose θnew; Charge-to-mass ratio deviation is expressed as the relative deviation of the residual toner charge-to-mass ratio QM_residual relative to the target new toner charge-to-mass ratio QM_new.

[0033] (2) Calculation formulas for each individual deviation (all deviations are dimensionless quantities):

[0034] In the formula, D 50，残 D represents the median particle size of the residual powder. 50，新The values ​​represent the median particle size of the target new toner, all in μm. Both measurements were taken using the same laser particle size analyzer under the same dispersion and testing conditions; if the target new toner reference value is unavailable, it is not calculated. K After supplementing the baseline value, a new judgment is made.

[0035]

[0036] In the formula, MC 残 and MC 新 Moisture content (MC) of residual toner and target new toner, respectively, on a wet basis, in %. The same method was used to determine the moisture content of the same batch. norm The normalized benchmark for moisture content deviation is the upper limit of the allowable difference specified in the model process library.

[0037]

[0038] In the formula, θ 残 and θ 新 The angles of repose for residual toner and target new toner are given in °, respectively, and were determined using the same angle of repose test method and the same sample loading conditions.

[0039]

[0040] In the formula, QM 残 and QM 新 The mass-to-charge ratios of residual toner and target new toner are given, in μC / g, and were determined under the same Faraday cage test conditions.

[0041] (3) Weighted summarization K value:

[0042] In the formula, , , , The median particle size D is as follows: 50 The weighted values ​​of wet basis moisture content, angle of repose, and charge-to-mass ratio; The median particle size D 50 The relative deviation; This represents the normalized deviation corresponding to the difference in moisture content on the wet basis. This refers to the relative deviation of the angle of repose. The relative deviation of the charge-to-mass ratio; in the preset weights The value is 0.30 to 0.40. The value is 0.20 to 0.30. The value is 0.15 to 0.25. It ranges from 0.15 to 0.25.

[0043] This implementation method uses the weights listed in Table 1; the four weights and MC corresponding to each toner cartridge model. norm The process parameters for each model are determined and fixed when they are first established, and the same parameters are used for calculations for the same model and the same batch. K The results will not be adjusted based on the test results of a single toner cartridge.

[0044] Deviations in particle size, moisture content, angle of repose, and charge-to-mass ratio are all converted to dimensionless values. When using the same type of new toner targeting the same target, its D... 50 Moisture content, angle of repose, and charge-to-mass ratio are recorded as baseline values ​​for this batch in the model process library.

[0045] Table 1 Residual Powder Compatibility Index K Recommended weights for various deviations

[0046] S3. Detect the remaining life percentage of each critical old component within the critical old component set I(M). L i The weights of the critical used parts actually existing in this model are normalized to a sum of 1, and a lifespan score is calculated. R ; Common candidate components include photosensitive imaging components, developing components, charging components, toner feeding components, toner dispensing control components, cleaning components, sealing components, and waste toner containers. After identifying the model number, only actually existing components are included in I(M); model-specific components are added separately. Components that do not exist are not counted. L i It also does not participate in weight normalization.

[0047] (1) R Calculated based on the normalized weights of the actual components within I(M). When the lifespan of a replaceable component is insufficient, a replacement judgment is entered; only defects that are irreparable and affect the integrity of the powder hopper housing, waste powder hopper housing, or drive interface are used to stop the reuse of the entire drum.

[0048] Lifespan rating R The calculation formula is as follows: The set I(M) is determined by the model structure identification results; each basic weight β i0 Normalizing only the actual components within I(M) yields β i And each β i The sum is 1.

[0049] L iThe remaining lifespan percentage of the i-th critical used part is 0% to 100%. Continuous degradation indicators are normalized to the new part value and the scrap threshold; when the same part has multiple indicators, the minimum value is taken; structural indicators are recorded as qualified or unqualified.

[0050] Basic weights in the key legacy component set I(M) Normalization is performed to obtain its weighted sum R The value is:

[0051] In the formula, β i For the first i The normalized weight values ​​of each key old component within set I(M) L i For the first i The remaining useful life percentage of each critical used component; the summation range only includes critical used components actually existing within I(M), each β i The sum is 1. L i The value range is from 0 to 100%.

[0052] Table 2 lists the basic relative weights and testing criteria for general candidate components. Only general components that actually exist for this model are included in I(M); model-specific components have separate basic relative weights in the model process library, and after being added to I(M), they are re-normalized together with the general components.

[0053] Table 2. Basic weights and testing criteria for general candidate components

[0054] (2) Percentage of remaining life of each component Quantitative standards to ensure lifespan scoring The computability is assessed by defining initial parameters, scrap thresholds, and remaining lifespan calculation formulas for each critical component as follows: ① Percentage of remaining lifespan of the photosensitive drum OPC:

[0055] in, The actual film thickness of the photosensitive drum. The initial film thickness of the photosensitive drum. The thickness of the film used for discarding the photosensitive drum is shown in μm. Under normal circumstances... Take 20μm, Take 8μm; if there are no scratches and no abnormal electrical performance, no deduction is made; if there are slight surface scratches but they do not affect printing, the calculated value will be used. Multiply by 0.8; if there are penetrating scratches or electrical performance degradation exceeding 30%, then =0%.

[0056] ②Developing roller D R Percentage of remaining lifespan:

[0057] in, This represents the measured resistance value of the current developing roller. 10 5 Ω, 10 8 Ω, This refers to the nominal resistance value of a new developing roller of the same model or a standard developing roller, and < < The resistance of the developing roller is lower than... or higher At that time, remaining lifespan The value is determined to be 0%; when it is within the reusable range, it is determined to be... As the optimal state reference, according to... Logarithmic deviation ratio calculation Surface roughness is expressed as the arithmetic mean roughness. R a Indicates; when R a Above 6.0 μm, for every 0.5 μm increase... A deduction of 20 percentage points will be applied, with a maximum deduction of 0%; this applies when annular wear bands, localized peeling, or coating damage occur. It is directly determined to be 0%.

[0058] ③ Charging roller (C) R Percentage of remaining lifespan:

[0059] in, R current This represents the measured resistance value of the current charging roller. 10 5 Ω, 10 8 Ω, The nominal resistance value is that of a new charging roller of the same model or a standard charging roller, and < < The resistance of the charging roller is lower than... or higher hour, =0% When within the reusable range, As the optimal state reference, according to... Logarithmic deviation ratio calculation When severe surface oxidation, elastic failure, cracking, or localized damage to the conductive layer occurs, It is directly determined to be 0%.

[0060] ④ Powder feeding rollers made of elastic material (S) R Or, the remaining life percentage of the powder supply roller (based on compression set):

[0061] in, This refers to the original thickness of the powder feeding roller. This is the thickness after compression. To restore thickness after release, The compression set is the compressive permanent deformation rate; `clip` indicates that the calculation results are limited to the range of 0% to 100%. When the compressive permanent deformation rate does not exceed 5%,... Take 100%, when it reaches or exceeds 30% Take 0%; when it is between 5% and 30%, calculate linearly using the formula; if the powder feeding roller surface is damaged, then... The result is directly set to 0%. Magnetic roller sleeves are not evaluated using this formula; they are classified as developing parts, and their remaining life is determined based on surface wear, resistance, or coating condition.

[0062] ⑤ Remaining lifespan percentage of the powder discharge blade (DB):

[0063] The initial wear depth is 0 mm, and the scrap threshold is 0.2 mm. When there is a notch with a length of not less than 1 mm on the cutting edge, it is directly judged as 0%. For every 0.1 mm that the straightness exceeds the allowable value, 20 percentage points are deducted.

[0064] ⑥ Remaining life percentage of cleaning scraper (CB) (also known as waste powder scraper):

[0065] 100% for intact condition; 50% for minor folds; 0% for notches, permanent bends, or severe deviations in contact angle.

[0066] ⑦ Remaining life percentage of seals (SE), for multiple seals, take the percentage of all seals. The minimum value is: 100% completely intact; 70% slight plastic deformation but no risk of powder leakage; 0% damage or permanent compression deformation >40%.

[0067] ⑧ Waste Powder Container (WC) Remaining Life Percentage:

[0068] Waste powder silos are generally structural components, and are judged using a binary standard of "qualified" or "unqualified"; in order to uniformly incorporate them into lifespan scoring... R Define the remaining lifespan of the waste powder silo. =100% indicates that the waste powder hopper is intact. =0% indicates that the waste powder hopper has cracks, deformation, excessive wear of the shaft hole, or other damage that affects its reuse.

[0069] (3) The actual remaining lifespan of components is determined using the following unified quantitative rules:

[0070] Here, 'clip' indicates that the calculation result is limited to the range of 0% to 100%; when the current value reaches or exceeds the scrap threshold, it is taken as 0%. For continuous indicators that decrease with degradation, the difference is taken in the opposite direction of the change in the new part value and the scrap threshold.

[0071] (4) When the same critical used part has more than two degradation indicators, calculate the remaining life percentage corresponding to each degradation indicator separately, and take the minimum value as the remaining life percentage of the critical used part. L i； (5) For cracks, fractures, permanent deformations or other structural indicators that are judged as qualified or unqualified, the percentage of remaining life is 100% when qualified and 0% when unqualified.

[0072] Key old parts that can be replaced individually L i Below L min When this happens, the critical old part is marked as a part to be replaced, and the partial replacement judgment is performed according to the judgment order described in S4; critical old parts that cannot be replaced individually... L i Below L min At this time, stop adding powder to the drum and proceed with disassembly and reuse. L i Below L min The defect itself is not a condition for rejecting the entire drum structure; only defects that cannot be eliminated by repair or component replacement and affect the integrity of the powder hopper housing, waste powder hopper housing, or drive interface will trigger a structural rejection.

[0073] S4, according to R and L i definition R and L i condition: R < R 1. Enter the material recycling process; R ≥ R 1 and existsL i < L min When critical old parts that cannot be replaced individually are available, they are used for disassembly and reuse; when no such critical old parts that cannot be replaced individually exist, they are not available. R 1≤ R < R 2. Disassemble and reuse parts. R 2≤ R < R 3 or R ≥ R 3 But it exists L i < L min When a critical, individually replaceable old part is identified, partial replacement conditions are entered. R ≥ R 3 and all L i ≥ L min When entering the condition of adding powder without changing parts; First lifetime threshold R 1 is 30%, the second lifespan threshold. R 2 is 60%, the third lifespan threshold. R 3 is 85%, the minimum component lifespan threshold. L min The first compatibility threshold is 60%. K 1 is 0.15, the second compatibility threshold. K 2 is 0.40; When the powder hopper housing, waste powder hopper housing, or drive interface has irreparable cracks, damage, or deformation, it is not considered. K and R The value of the drum is used to prohibit the reuse of the entire drum; There are no irreparable structural defects. R ≥ R 3 and all L i ≥ L min At that time, it was a candidate for adding powder directly without changing parts; There are no irreparable structural defects, and R 2≤ R < R 3, or R ≥ R 3 But it exists L i < L min When a critical old part can be replaced individually, it is a candidate for adding powder after replacement. R 1≤ R <R 2, or R ≥ R 2 and exist L i < L min Furthermore, if critical old parts that cannot be replaced individually, or if the powder filling access conditions are still not met after partial replacement, they will be disassembled and reused. R < R At 1 o'clock, the material recycling process begins.

[0074] S5, Construction K - R Joint judgment matrix, setting lifespan score R and percentage of remaining lifespan L i Compatibility index with residual powder K The processing results are listed in columns, with each matrix row consisting of a lifespan score. R and percentage of remaining lifespan L i With a residual powder compatibility index K Commonly defined; the processing results include material recycling, dismantling and reuse, partial replacement with powder addition or no replacement with powder addition; Preset the first lifespan threshold R 1. Second lifetime threshold R 2. Third lifespan threshold R 3. Minimum component lifespan threshold L min First compatibility threshold K 1 and second compatibility threshold K 2, where 0 < R 1 < R 2< R 3≤100%, 0< L min ≤100%, 0 < K 1 < K 2; According to lifespan rating R Percentage of remaining useful life of each critical old component L i Compatibility index with residual powder K ,based on K - R The joint judgment matrix outputs the processing result, where: R < R Material recycling begins at 1 o'clock; R ≥ R 1 and exists L i < L minFurthermore, if critical old parts cannot be replaced individually, they are used for disassembly and reuse; if no such critical old parts cannot be replaced individually, R 1≤ R < R 2. Disassemble and reuse parts. R 2≤ R < R 3 or R ≥ R 3 But it exists L i < L min When key old parts can be replaced individually, partial replacement conditions are entered. R ≥ R 3 and all L i ≥ L min When entering the condition of adding powder without changing parts; K > K 2. K 1 < K ≤ K 2 and K ≤ K 1 corresponds to complete powder removal, partial powder removal, and low-percentage residual powder retention, respectively; Among them, construct KR When using a joint judgment matrix, set the following respectively: R and L i condition column, K The condition column and the processing result column specifically include: (1) If there are irreparable structural defects before entering the matrix, it is not considered. K , R and L i The value of [value] indicates that the reuse of the entire drum should be stopped and the process should begin material recycling. (2) The above R and L i The condition column includes R < R 1, R 1≤ R < R 2, R ≥ R 2 and exist L i < L min And critical old parts that cannot be replaced individually. R 2≤ R < R 3 or R ≥ R 3 But it existsL i < L min Key old parts that can be replaced individually, and R ≥ R 3 and all L i ≥ L min ; (3) The above K The condition column includes K > K 2. K 1 < K ≤ K 2 and K ≤ K 1. These correspond to completely removing powder, partially removing powder, and retaining a low percentage of residual powder, respectively. (4) R < R 1 and any K Output material recovery when conditions are combined; R 1≤ R < R 2, or R ≥ R 2 and exist L i < L min When a critical old part cannot be replaced individually, it is related to any K All combinations of conditions output the components for reuse. R ≥ R 3 and all L i ≥ L min At that time, according to the corresponding K Conditional output options include: complete powder cleaning and refilling without changing parts; partial powder cleaning and refilling without changing parts; or low-percentage residual powder retention and refilling without changing parts. (5) When it falls under the condition of partial replacement, if there are L i < L min If critical old parts cannot be replaced individually, then stop adding toner to the entire drum and proceed with disassembly and reuse; otherwise, follow the procedures outlined below. L i Select the key old parts that can be replaced individually in ascending order of their quality, and replace them first. L i < L min The key old parts will be replaced as needed. R 'achieve R 3. Required key old parts, and recalculation. R 'and Li′ ; R ′≥ R 3 and all L i′ ≥ L min At that time, according to the corresponding K If conditions are met, perform powder cleaning and powder addition; otherwise, proceed with disassembly and utilization.

[0075] When replacing parts, if there are L i Below L min For critical old parts that cannot be replaced individually, they are then disassembled and reused; for critical old parts that can be replaced individually, they are handled according to... L i Select in ascending order, replacing first. L i Below L min The key old parts will be replaced as needed. R 'achieve R 3. Required key spare parts; The replaced component uses the test value after replacement. L i′ The original parts were not replaced. L i Or re-detect the value; each L i′ Recalculate using the normalized weights of the model set I(M). R ′; R ′≥ R 3 and all L i′ ≥ L min At that time, according to K Adding powder is allowed after the corresponding degree of powder removal treatment; R ′< R 3 or still exists L i′ < L min At this time, stop adding powder to the drum and proceed with disassembly and reuse.

[0076] For example, S2 determines K Conditions determined by S4 R and L i Input the conditions into Table 3 and read the processing results corresponding to the matrix rows that simultaneously satisfy both types of conditions; When the condition falls under partial replacement, according to Li Select the key old parts that can be replaced individually in ascending order of their quality, and replace them first. L i < L min The key old parts will be replaced as needed. R 'achieve R 3. Required key old parts, and recalculation. R 'and L i′ ; R ′≥ R 3. All L i′ ≥ L min At that time, in accordance with the corresponding K Conditional powder cleaning and powder addition; After replacement R ′< R 3 or still exists L i′ < L min When the material is recycled or the dismantled parts are utilized, it will proceed to the dismantling and utilization stage; once the results of material recycling or dismantling and utilization are determined, it will no longer proceed to the powder addition process. If the condition for adding powder without replacing parts applies, proceed directly according to the corresponding procedure. K Under certain conditions, complete powder removal, partial powder removal, or retention of a low proportion of residual powder are performed before quantitative powder addition. Table 3 first applies a pre-emptive veto based on structural defects; if no structural veto is triggered... R and L i conditional sum K The conditions are listed separately, and the processing results are given in the same matrix row.

[0077] The matrix lists material recycling, dismantling and reuse, powder addition after partial component replacement, and powder addition without component replacement from top to bottom, and also includes... R and L i Conditional columns and K The corresponding thresholds are given in the condition column.

[0078] Each toner cartridge consists of one R and L i Conditions and one K The processing result is determined by the combined conditions; R Life rating before replacement. R ′ represents the recalculated value after the replacement.

[0079] Table 3 KR Joint judgment matrix

[0080] In Table 3, structural rejection takes precedence over matrix judgment; R < R At 1 o'clock, the material recycling process begins. R ≥ R 1 and exists L i < L min When critical old parts cannot be replaced individually, they are disassembled for reuse; under partial replacement conditions, the replacement process begins according to the conditions before replacement, and only after replacement... R ′≥ R 3 and all L i′ ≥ L min Only then will the corresponding action be executed. K The results of powder cleaning and powder addition corresponding to the conditions.

[0081] In this embodiment, R 1. R 2. R 3 and L min Take 30%, 60%, 85%, and 60% respectively. K 1 and K 2. The values ​​are 0.15 and 0.40 respectively. The above values ​​are the preset parameters used in the HP 147X calculation example and do not constitute a limitation on the thresholds of other models.

[0082] S6. Weigh the toner cartridge that allows for refilling to determine the mass of residual old toner after cleaning (M). res and according to M add =M target M res Replenish target new toner, of which M target M represents the target total powder mass specified in the model process library. add The actual quality of the new toner added; after completing the quantitative toner addition, seal the original toner inlet or the process toner inlet; After adding toner, at least check the sealing of the toner filling port and the print quality. If the sealing or printing quality is not up to standard, it should be reworked. If it is still not up to standard after rework, the whole drum should be removed from the machine for reuse. Toner cartridges that have been refilled are not permitted to be used for disassembly or material recycling. The toner cartridge model and the actual component assembly I(M) K , R , R ′、 L i , L i′The matrix rows used, the degree of toner removal, the replacement items, the amount of toner added, the sealing inspection results, the printing quality results, and the final judgment are written into the traceability database.

[0083] See Figure 3 As shown, the rear-mounted self-locking pressure relief and anti-backflow toner filling valve is an implementation structure for situations requiring a rear-mount toner filling interface. It includes a valve seat 301, a toner path channel 302, a one-way valve core 303, an independent pressure relief channel 304, a labyrinth toner blocking structure 305, a toner blocking filter element 306, a rotating locking cover 307, a locking mechanism 308, and an elastic sealing ring 309. The valve seat 301 is sealed to the toner filling port of the toner hopper via the elastic sealing ring 309; the one-way valve core 303 is located within the toner path channel 302; the independent pressure relief channel 304 is isolated from the toner path channel 302, with one end connected to the toner hopper air chamber and the other end connected to the outside; the labyrinth toner blocking structure 305 and the toner blocking filter element 306 are arranged along the direction of the pressure relief airflow. The dedicated toner filling connector 310 is an external mating part that temporarily connects to the toner path channel 302 during toner filling; the new toner flow direction indicator 311 only indicates the toner flow direction.

[0084] During toner refilling, the dedicated toner refill connector 310 is inserted into the toner path channel 302 and opens the one-way valve core 303, allowing new toner to enter the toner hopper along the toner path channel 302. The displaced air in the toner hopper is discharged through the independent pressure relief channel 304, and the entrained toner settles and deflects in the labyrinthine toner-blocking structure 305, where it is further trapped by the toner-blocking filter element 306. After refilling, the dedicated toner refill connector 310 is withdrawn, the one-way valve core 303 resets and closes, the rotating locking cover 307 is locked, and the elastic sealing ring 309 maintains the seal of the toner refill port. The locking mechanism 308 confirms the locking status. Toner cartridges with resealable refill ports can employ docking and sealing methods compatible with this refill port process.

[0085] Figure 3 The structure shown is only used when adding powder after replacing the component as shown in Table 3, or when adding powder without replacing the component. During operation, first complete the installation and locking confirmation of the powder adding valve, then connect the dedicated powder adding connector 310; do not start the quantitative powder adding process if the locking is not confirmed or the seal is not properly installed. This structure is used to achieve sealing and pressure relief of the powder adding interface and does not participate in... K , R and L i The calculation.

[0086] See Figure 4As shown, the quantitative toner addition and leak prevention test station includes a station frame 401, a toner hopper 402, a metering toner supply assembly 403, a toner addition connector 404, a drum positioning fixture 405, a pressure source 406, an inversion and flipping mechanism 407, a vibration table 408, a toner leakage collection tray and a camera 409, and a PLC or industrial computer 410. The metering toner supply assembly 403 includes a loss-in-weight weighing unit and a metering screw controlled by its feedback; the toner hopper 402, the metering toner supply assembly 403, and the toner addition connector 404 are connected along the toner supply direction; the drum positioning fixture 405 is located below the toner addition connector 404; the pressure source 406 is connected to the test interface; the inversion and flipping mechanism 407 and the vibration table 408 are used to change the drum posture and apply vibration; the toner leakage collection tray and the camera 409 are used to collect and record escaped toner. Figure 4 The mark 403 indicates the metering powder supply component 403.

[0087] When this workstation is operating, the PLC or industrial computer 410 reads the toner cartridge model, the processing results in Table 3, and M... target Receive the weighed and determined M res And calculate M add =M target M res Then, based on the feedback control of the loss-in-weight weighing unit, the metering screw in the metering powder supply assembly 403 supplies M to the powder feeding connector 404. add The quality target is new toner. After adding toner and sealing the filling port, pressure source 406 is used to check the seal; if inversion or vibration checks are required, the inversion mechanism 407 and vibration table 408 are activated respectively, and the leakage collection tray and camera 409 record the leakage location and collection status. The above inspection items are selected according to the model process requirements.

[0088] During operation, insert the toner cartridge into the toner cartridge positioning fixture 405 and align the toner filling connector 404 with the toner filling port. Input the M corresponding to the model number. target M was determined by weighing after cleaning the powder. res PLC or industrial computer 410 calculation M add =M target M res Then start metering and powder supply; to reach M add Stop toner supply and seal the toner inlet. Then perform a sealing check, as well as inversion and vibration checks according to model requirements. After the station checks are completed, install the machine for print quality checks, and then... target M res M add The inspection results and final judgment are written into the traceability record.

[0089] This process is applicable to office toner cartridges with a high nominal print volume (over 20,000 pages), toner refillable cartridges, and key old components that can be inspected or replaced. Table 4 lists three examples of toner cartridge models; specific toner refill amounts, component sets, and inspection thresholds should be recorded in the corresponding model's process library.

[0090] Table 4 Examples of High-Burst Office Toner Cartridge Models

[0091] The calculation process is illustrated below using the HP 147X (W1470X) as an example. The listed test values ​​are for demonstration purposes. K , R The method for determining the processing path should be replaced by the test record of this toner cartridge during actual production.

[0092] This calculation example calls the parameters pre-set in the model process library: R 1=30%, R 2=60%, R 3=85%, L min =60% K 1 = 0.15 K 2 = 0.40. This set of values ​​is used to illustrate the joint judgment process and does not mean that all models use the same threshold.

[0093] Structural inspection: The powder hopper shell, waste powder hopper shell, and drive interface have no irreparable cracks or deformations, and the inspection can continue. K and R The calculation.

[0094] K Calculation: Let the normalized deviations of particle size, moisture content, angle of repose, and charge-to-mass ratio be 0.08, 0.10, 0.05, and 0.06, respectively, and their weights be 0.35, 0.25, 0.20, and 0.20, respectively. K =0.35×0.08+0.25×0.10+0.20×0.05+0.20×0.06=0.075; Since K =0.075≤ K 1 = 0.15, corresponding to a low proportion of residual powder retained.

[0095] Component set and model-specific component calculation: Include the common components, powder supply screw, and drive coupling assembly that actually exist for this model in I(M). The wear clearance of the powder supply screw increases from 0.05 mm for new parts to the scrap threshold of 0.55 mm; in this example, we take 0.16 mm, corresponding to 78% of the remaining life. The drive torque corresponds to 82% of the remaining life; therefore, this component... L iTake 78%. The tooth backlash and transmission torque of the drive coupling assembly correspond to 86% and 90% respectively, and the crack inspection is qualified. L i Take 86%. The basic relative weights of the two model-specific components are both 0.05, and are calculated after normalization together with the general components. R .

[0096] Table 5 shows a calculation example for HP 147X. R enter

[0097] Joint judgment: K =0.075≤ K 1. The condition of low residual powder retention is met; Table 5 shows the calculation results. R =82.70%, which satisfies the requirement. R 2≤ R < R 3. And powder dispensing control components L i =55%< L min =60%, therefore, it enters the partial component replacement condition. In Table 3, the matrix rows that simultaneously meet both of the above conditions will first undergo partial component replacement. After component replacement, it will proceed according to... L i′ =100% recalculation yields R =87.20%≥ R 3 = 85%, the rest L i′ All are no less than L min Through component replacement and verification, the final implementation involves retaining a low proportion of residual powder and adding powder in a quantitative manner.

[0098] Table 6 Existing manual assessment methods and K - R Comparison of Judgment Criteria and Processing Results of Joint Judgment Methods

[0099] Table 6 compares existing manual assessment methods with... K - R The judgment inputs, processing methods, and result records of the joint judgment method shall not be used as experimental conclusions regarding print life, toner leakage rate, or economy.

[0100] This invention also provides a system for implementing the above-mentioned graded reuse process, including a data processing device, a model process library, a residual powder detection device, a used part life testing device, a closed negative pressure powder cleaning station, a quantitative powder addition and inspection station, and a model identification and structure inspection module, a matrix judgment module, and a recording module running in the data processing device. The detection data from the residual powder detection device and the used part life testing device are transmitted to the data processing device, which then calls the model process library to complete the process. K , R or R′ The calculation is performed, and the matrix processing instructions are sent to the corresponding execution station.

[0101] The model identification and structural inspection module is used to identify the toner cartridge model, establish I(M), call the corresponding model process parameters, and record irreparable structural defects. The residual toner detection device is used to obtain the particle size, moisture content, angle of repose, and mass-to-charge ratio of residual toner and target new toner, and transmits the detection values ​​to the data processing device for calculation. K ; The used parts life testing device is used to obtain the degradation index test values ​​of each key used part within I(M), and transmit the test values ​​to the data processing device to calculate each... L i as well as R or R′ ; The matrix judgment module is used to determine the final result after the structure check has passed. R and L i conditional sum K Conditional input KR The joint judgment matrix determines the whole drum reuse processing result based on the matrix row that simultaneously satisfies two types of conditions, and outputs processing instructions to the closed negative pressure powder cleaning station and the quantitative powder addition and inspection station. The closed negative pressure cleaning station and the quantitative powder addition and inspection station are used to receive processing instructions and perform cleaning, partial replacement of parts, powder addition, sealing inspection, disassembly and reuse or material recycling. The recording module is used to receive data transmitted back from each detection device and execution station, and to save the detection input, judgment basis and final processing results.

[0102] The above embodiments are used to illustrate the technical solutions of the present invention and do not limit the scope of protection of the present invention. Equivalent substitutions or conventional modifications made by those skilled in the art without departing from the technical features and effects defined in the claims should fall within the scope of protection of the present invention.

Claims

1. A leak-proof toner reuse process for regenerated toner cartridges based on residual toner compatibility determination and reuse level routing, characterized in that, include: Identify the model of the recycled toner cartridge and establish a set of key used parts I(M) for that model. Inspect the toner cartridge housing, waste toner cartridge housing, and drive interface of the recycled toner cartridge for defects that cannot be eliminated by repair or component replacement. Defects include cracks, damage, or deformation. If defects that cannot be eliminated by repair or component replacement are present, the entire cartridge must not be reused. When whole-drum reuse is not prohibited, residual toner samples are collected, and the differences between the residual toner and the target new toner compatible with this model in terms of particle size, moisture content, angle of repose, and mass-to-charge ratio are detected. The residual toner compatibility index is then calculated. K ; Detect the remaining useful life percentage of each critical used component within the critical used component set I(M). L i The weights of the critical used parts actually existing in this model are normalized to a sum of 1, and a lifespan score is calculated. R ; Build K - R Joint judgment matrix, setting lifespan score R and percentage of remaining lifespan L i Compatibility index with residual powder K The processing results are listed in columns, with each matrix row consisting of a lifespan score. R and percentage of remaining lifespan L i With a residual powder compatibility index K Commonly defined; the processing results include material recycling, dismantling and reuse, partial replacement of parts followed by powder addition, or powder addition without replacement of parts; Preset the first lifespan threshold R 1. Second lifetime threshold R 2. Third lifespan threshold R 3. Minimum component lifespan threshold L min First compatibility threshold K 1 and second compatibility threshold K 2, where 0 < R 1 < R 2< R 3≤100%, 0< L min ≤100%, 0 < K 1 < K 2; According to lifespan rating R Percentage of remaining useful life of each critical old component L i Compatibility index with residual powder K ,based on K - R The joint judgment matrix outputs the processing result, where: R < R Material recycling begins at 1 o'clock; R ≥ R 1 and exists L i < L min Furthermore, if critical old parts cannot be replaced individually, they are used for disassembly and reuse; if no such critical old parts cannot be replaced individually, R 1≤ R < R 2. Disassemble and reuse parts. R 2≤ R < R 3 or R ≥ R 3 But it exists L i < L min When key old parts can be replaced individually, partial replacement conditions are entered. R ≥ R 3 and all L i ≥ L min When entering the condition of adding powder without changing parts; K > K 2. K 1 < K ≤ K 2 and K ≤ K 1 corresponds to complete powder removal, partial powder removal, and low-percentage residual powder retention, respectively; Among them, the processing results determine the toner cartridges that are allowed to be refilled, and the residual old toner mass M after cleaning is weighed to determine the mass. res and according to M add =M target M res After replenishing with the target new toner, seal the toner inlet, where M target M represents the target total powder mass specified in the model process library. add The actual mass of the new toner added; After adding toner, a sealing check and a print quality check are performed, and the output is either qualified, reworked, or returned for reuse as a whole drum.

2. The process for reusing leak-proof toner cartridges according to claim 1, characterized in that, The residual powder compatibility index K Used to determine the degree of powder removal: K ≤ K At time 1, a low proportion of residual powder is retained; K 1 < K ≤ K Partial powder removal is used at 2 o'clock; K > K Complete powder removal is performed at time 2; The low percentage of residual powder retention refers to the amount of residual old powder (M) remaining in the powder hopper and developing area after cleaning visible agglomerated powder and waste powder. res Greater than the target total powder mass M of the model target 1% and not exceeding M target 5%; The term "partial powder cleaning" refers to removing visible residual powder from the powder container and developing area, ensuring that 0 < M. res ≤M target 1%, and has not yet met the criteria for complete powder removal; The complete toner cleaning refers to emptying the toner hopper, developing area, and waste toner holding area of ​​the old toner and cleaning the toner supply channel, so that M res The weighing resolution is 0 and there is no visible residual powder in the above area; M target M represents the target total powder mass specified in the model process library. res It is determined by the difference between the weighing value after cleaning and the baseline mass of the empty chamber of the same model.

3. The process for reusing leak-proof toner cartridges according to claim 1, characterized in that, The critical used parts set I(M) was determined from general candidate parts and model-specific parts; The general candidate components include the photosensitive imaging element, developing element, charging element, toner feeding element, toner dispensing control element, cleaning element, sealing element, and waste toner container that are actually present in this model. The model-specific components are determined by the model process library based on the actual structure of the model, and added to set I(M) after their actual existence is confirmed; If a candidate component does not exist in this model, it is not set. L i And prevent it from participating with a zero value. R Calculation; Basic weights in the key legacy component set I(M) Normalization is performed to obtain , and according to Calculate lifespan score R ; For any critical used part in the critical used parts set I(M), obtain the current detection value of the degradation index corresponding to the critical used part, the benchmark value of the new part of the same model, and the scrapping threshold; for degradation indices that continuously increase or decrease with the degree of degradation, according to the direction of change of the degradation index, with the new part benchmark value corresponding to 100% and the scrapping threshold corresponding to 0%, the current detection value is linearly converted into the remaining life percentage corresponding to the degradation index; when the current detection value reaches or exceeds the new part benchmark value, it is taken as 100%, and when it reaches or exceeds the scrapping threshold, it is taken as 0%. When a critical used part has more than two degradation indicators, the remaining useful life percentage corresponding to each degradation indicator is determined separately, and the minimum value among them is taken as the remaining useful life percentage of the critical used part. L i For structural indicators such as cracks, fractures, or other defects that are judged as qualified or unqualified, the remaining life percentage is taken as 100% when qualified and 0% when unqualified. Key old parts that can be replaced individually L i Below L min At that time, the critical old part is marked as a replacement part, and the entire drum does not trigger a structural veto and life score is calculated. R When the conditions for partial replacement are met, the partial replacement process begins; critical old parts that cannot be replaced individually... L i Below L min At this time, stop adding powder to the entire drum and proceed with disassembly and reuse; L i Below L min The structure itself is not a rejection condition for the entire drum structure. The rejection is triggered by defects in the powder hopper housing, waste powder hopper housing, or drive interface that cannot be eliminated by repair or component replacement.

4. The process for reusing leak-proof toner cartridges according to claim 1, characterized in that, First lifetime threshold R 1 is 30%, the second lifespan threshold. R 2 is 60%, the third lifespan threshold. R 3 is 85%, the minimum component lifespan threshold. L min The first compatibility threshold is 60%. K 1 is 0.15, the second compatibility threshold. K 2 is 0.40; When the powder hopper housing, waste powder hopper housing, or drive interface has irreparable cracks, damage, or deformation, it is not considered. K and R The value of the drum is used to prohibit the reuse of the entire drum; There are no irreparable structural defects. R ≥ R 3 and all L i ≥ L min At that time, it was a candidate for adding powder directly without changing parts; There are no irreparable structural defects, and R 2≤ R < R 3, or R ≥ R 3 But it exists L i < L min When a critical old part can be replaced individually, it is a candidate for adding powder after replacement. R 1≤ R < R 2, or R ≥ R 2 and exist L i < L min Furthermore, if critical old parts that cannot be replaced individually, or if the powder filling access conditions are still not met after partial replacement, they will be disassembled and reused. R < R At 1 o'clock, the material recycling process begins.

5. The process for reusing leak-proof toner cartridges according to claim 1, characterized in that, Build KR When using a joint judgment matrix, set the following respectively: R and L i condition column, K The condition column and the processing result column specifically include: (1) If there are irreparable structural defects before entering the matrix, it is not considered. K , R and L i The value of [value] indicates that the reuse of the entire drum should be stopped and the process should begin material recycling. (2) The above R and L i The condition column includes R < R 1, R 1≤ R < R 2, R ≥ R 2 and exist L i < L min And critical old parts that cannot be replaced individually. R 2≤ R < R 3 or R ≥ R 3 But it exists L i < L min Key old parts that can be replaced individually, and R ≥ R 3 and all L i ≥ L min ; (3) The above K The condition column includes K > K 2. K 1 < K ≤ K 2 and K ≤ K 1. These correspond to completely removing powder, partially removing powder, and retaining a low percentage of residual powder, respectively. (4) R < R 1 and any K Output material recovery when conditions are combined; R 1≤ R < R 2, or R ≥ R 2 and exist L i < L min When a critical old part cannot be replaced individually, it is related to any K All combinations of conditions output the components for reuse. R ≥ R 3 and all L i ≥ L min At that time, according to the corresponding K Conditional output options include: complete powder cleaning and refilling without changing parts; partial powder cleaning and refilling without changing parts; or low-percentage residual powder retention and refilling without changing parts. (5) When it falls under the condition of partial replacement, if there are L i < L min If critical old parts cannot be replaced individually, then stop adding toner to the entire drum and proceed with disassembly and reuse; otherwise, follow the procedures outlined below. L i Select the key old parts that can be replaced individually in ascending order of their quality, and replace them first. L i < L min The key old parts will be replaced as needed. R 'achieve R 3. Required key old parts, and recalculation. R 'and L i′ ; R ′≥ R 3 and all L i′ ≥ L min At that time, according to the corresponding K If conditions are met, perform powder cleaning and powder addition; otherwise, proceed with disassembly and utilization.

6. The process for reusing leak-proof toner powder in a regenerated toner cartridge according to claim 5, characterized in that, When replacing parts, if there are L i Below L min For critical old parts that cannot be replaced individually, they are then disassembled and reused; for critical old parts that can be replaced individually, they are handled according to... L i Select in ascending order, replacing first. L i Below L min The key old parts will be replaced as needed. R 'achieve R 3. Required key spare parts; The replaced component uses the test value after replacement. L i′ The original parts were not replaced. L i Or re-detect the value; each L i′ Recalculate using the normalized weights of the model set I(M). R ′; R ′≥ R 3 and all L i′ ≥ L min At that time, according to K Adding powder is allowed after the corresponding degree of powder removal treatment; R ′< R 3 or still exists L i′ < L min At this time, stop adding powder to the drum and proceed with disassembly and reuse.

7. The process for reusing leak-proof toner cartridges according to claim 1, characterized in that, Weigh the toner cartridges that are allowed to be refilled to determine the mass M of residual old toner after cleaning. res and according to M add =M target M res Replenish target new toner, of which M target M represents the target total powder mass specified in the model process library. add The actual quality of the new toner added; after completing the quantitative toner addition, seal the original toner inlet or the process toner inlet; After adding toner, at least check the sealing of the toner filling port and the print quality. If the sealing or printing quality is not up to standard, it should be repaired. If it is still not up to standard after repair, the whole drum should be removed from the service for reuse.

8. The process for reusing leak-proof toner cartridges according to claim 1, characterized in that, The residual powder compatibility index K The median particle size D of the residual toner and the target new toner 50 The normalized deviations of moisture content, angle of repose, and charge-to-mass ratio are calculated using the following formulas: In the formula, each deviation term is a non-negative dimensionless value; the sum of all weights is 1, where the particle size term has a weight of 0.30–0.40, the moisture content term has a weight of 0.20–0.30, and the angle of repose and charge-to-mass ratio terms have weights of 0.15–0.25 respectively. The four weights and the normalized moisture content reference MC corresponding to each toner cartridge model are also provided. norm The model process must be determined and fixed in the model process library before testing, and the same model must not be temporarily adjusted based on the test results.

9. The process for reusing leak-proof toner cartridge powder according to claim 1, characterized in that, Also includes: The toner cartridge model and the actual component assembly I(M) K , R , R ′、 L i , L i′ The matrix rows used, the degree of toner removal, the replacement items, the amount of toner added, the sealing inspection results, the printing quality results, and the final judgment are written into the traceability database.

10. A system for implementing the regenerated toner cartridge anti-leakage toner reuse process as described in claim 1, characterized in that, It includes a data processing device, a model process library, a residual powder detection device, a used part life detection device, a closed negative pressure powder cleaning station, and a quantitative powder addition and inspection station; the residual powder detection device and the used part life detection device are connected to the data processing device, which calls preset parameters from the model process library to perform... K , R or R′ Calculate and output KR Joint judgment result; The model identification and structural inspection module runs on the data processing device and is used to determine the actual component set I(M), call the corresponding model process parameters, and record irreparable structural defects. The residual powder detection module includes a residual powder detection device for obtaining particle size, moisture content, angle of repose, and charge-to-mass ratio detection values, and for transmitting the detection values ​​to a data processing device for calculation. K ; The used component life testing module includes a used component life testing device for obtaining at least one of the following test values: film thickness, resistance, surface roughness, dimensions, or drive torque; and for transmitting the test values ​​to a data processing device and calculating the values. L i as well as R or R′ ; The matrix judgment module, running in the data processing device, is used to determine the matrix after the structural check has passed. R and L i conditional sum K Conditional input KR The joint judgment matrix is ​​used, and processing instructions are output to the closed negative pressure powder cleaning station and the quantitative powder addition and inspection station based on the matrix row that simultaneously meets the two types of conditions. The reuse execution and recording module includes the sealed negative pressure powder cleaning station and the quantitative powder addition and inspection station. It is used to receive processing instructions, perform powder cleaning, partial component replacement, powder addition, sealing inspection or exit the whole drum reuse, and transmit the detection input, judgment basis and processing results back to the data processing device for storage.

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