Image forming apparatus

Abstract

To reduce an operation stop period.SOLUTION: An image forming apparatus according to the present disclosure comprises: a containing mechanism for replacement members storing toner for performing image formation; opening and closing members that are provided at attachment and detachment ports of the replacement members accommodated in the containing mechanism; a lock mechanism for locking the opening and closing members in a closed state; a cover member that is openable and closable, and covers the opening and closing members and prevents the opening and closing members from opening when it is closed; a detection unit that detects whether the cover member is closed; and a failure detection unit that, when it is detected that the cover member is closed and when it is determined that the amount of the toner stored in the replacement members is smaller than a predetermined threshold, executes failure detection as to whether the lock achieved by the lock mechanism can be released.SELECTED DRAWING: Figure 6

Description

[Technical Field]

[0001] The present invention relates to an image forming apparatus. [Background technology]

[0002] 2. Description of the Related Art Conventionally, image forming apparatuses are configured to be able to accommodate a toner bottle that stores toner for forming images.

[0003] For example, in Patent Document 1, a toner bottle cover is provided at an attachment / detachment opening for attaching and detaching a toner bottle. The image forming apparatus is provided with a toner bottle cover solenoid (an example of a locking mechanism) that locks the toner bottle cover to prevent a user from accidentally removing the toner bottle. Summary of the Invention [Problem to be solved by the invention]

[0004] In image forming devices equipped with a locking mechanism for locking the toner bottle cover, if the locking mechanism malfunctions, the toner bottle cover cannot be opened. In conventional image forming devices, it is often the case that a malfunction of the locking mechanism is only realized when the locking mechanism cannot be released to replace the toner bottle.

[0005] That is, when the toner bottle needs to be replaced in the image forming apparatus, the toner bottle cannot be replaced until the locking mechanism is repaired, which causes a problem of the image forming apparatus being down for a long period of time.

[0006] In view of the above-mentioned problems, an embodiment of the present invention aims to reduce the period of downtime of an image forming apparatus by detecting a failure in a locking mechanism at an appropriate timing. [Means for solving the problem]

[0007] In order to solve the above-mentioned problems, the present invention provides an image forming apparatus comprising: a storage mechanism for a replaceable part that stores toner for image formation; an open / close member provided at an attachment / detachment opening for the replaceable part housed in the storage mechanism; a locking mechanism for locking the open / close member in a closed state; a cover member that is openable and closable and that covers the open / close member when closed and prevents the open / close member from being opened; a detection unit that detects whether the cover member is in a closed state; and a fault detection unit that performs fault detection to determine whether the locking mechanism can be switched to an unlocked state when it is detected that the cover member is in a closed state and when it is determined that the amount of toner housed in the replaceable part is less than a predetermined threshold. [Effects of the Invention]

[0008] According to an embodiment of the present invention, by detecting a malfunction of the locking mechanism at an appropriate timing, it is possible to reduce the downtime of the image forming apparatus. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a diagram illustrating an example of a configuration of an image forming apparatus according to a first embodiment. [Figure 2] 1 is a perspective view showing a state in which a front cover of an image forming apparatus according to a first embodiment is open. [Figure 3] FIG. 2 is an explanatory diagram showing a state in which the front cover of the image forming apparatus according to the first embodiment is open and the corresponding bottle cover is open. [Figure 4] FIG. 2 is a perspective view showing the bottle cover according to the first embodiment in an open state. [Figure 5] 3 is an explanatory view of the locking mechanism of the bottle cover according to the first embodiment, viewed from the X direction. FIG. [Figure 6] FIG. 2 is a diagram illustrating the configuration of a control unit according to the first embodiment. [Figure 7] 2 is an explanatory diagram showing an example of the configuration of a drive control unit including a solenoid failure detection circuit according to the first embodiment. FIG. [Figure 8]10 is a flowchart showing a first execution procedure for detecting a failure in which a solenoid does not turn ON (unlocked state failure), which is performed in the image forming apparatus according to the first embodiment. [Figure 9] 10 is a flowchart showing a second execution procedure for detecting a failure in which the solenoid does not turn ON (unlocked state failure), which is performed in the image forming apparatus according to the first embodiment. [Figure 10] 10 is a flowchart showing a first execution procedure for detecting a malfunction in which a solenoid does not turn off (locked state malfunction), which is performed in the image forming apparatus according to the first embodiment. [Figure 11] 10 is a flowchart showing a second execution procedure for detecting a malfunction in which the solenoid does not turn off (locked state malfunction), which is performed in the image forming apparatus according to the first embodiment. [Figure 12] FIG. 12 is a diagram illustrating the configuration of a control unit according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments will be described with reference to the accompanying drawings. In order to facilitate understanding of the description, the same components in the drawings will be denoted by the same reference numerals as much as possible, and overlapping will be avoided. The explanation will be omitted.

[0011] Hereinafter, an embodiment will be described taking as an example an electrophotographic image forming apparatus equipped with a secondary transfer mechanism called a tandem system.

[0012] (First embodiment) The image forming apparatus according to the present embodiment may be, for example, a multifunction full-color digital copier (MFP (Multifunction Peripheral)) that forms color images by electrophotography. Fig. 1 is a diagram showing an example of the schematic configuration of the image forming apparatus according to the present embodiment.

[0013] This image forming device is an MFP (Multifunction Peripheral / Printer / Product) that incorporates copy, print, facsimile, and other functions in a single housing. Examples of recording media include plain paper, which is generally used for copying, overhead projector sheets (OHP sheets), thick paper such as cards and postcards, and envelopes, but paper will be used as an example of a recording medium in this description.

[0014] <Configuration Example of Image Forming Apparatus 100> 1 is a diagram showing an example of the configuration of an image forming apparatus 100 according to an embodiment, and is a cross-sectional view showing a main part of the image forming apparatus 100 according to the embodiment. As shown in FIG. 1, the image forming apparatus 100 has an intermediate transfer unit at the center, which has an intermediate transfer belt 10, which is an endless belt. The intermediate transfer belt 10 is wound around three support rollers 14 to 16 and is driven to rotate clockwise.

[0015] The image forming apparatus 100 also includes an intermediate transfer member cleaning unit 17, located to the left of the second support roller 15 of the three support rollers 14 to 16, for removing residual toner remaining on the intermediate transfer belt 10 after image transfer.

[0016] An image forming unit 20 consisting of a yellow (Y) image forming unit, a magenta (M) image forming unit, a cyan (C) image forming unit, and a black (K) image forming unit is provided facing the intermediate transfer belt 10 arranged between the first support roller 14 and the second support roller 15, and the image forming units for each color are arranged along the movement direction of the intermediate transfer belt 10.

[0017] The imaging units for each color have the same configuration except for the color of toner they use. Therefore, in the explanations and drawings, the suffixes "Y," "M," "C," and "K" that indicate the color of toner used may be omitted as appropriate.

[0018] The image forming unit 20 includes photosensitive drums (image carriers) 40 (40Y, 40M, 40C, 40K) for each color, charging rollers 18 (18Y, 18M, 18C, 18K), a developing unit, and a cleaning unit, and is detachably mounted on the image forming device 100.

[0019] The image forming apparatus 100 is provided with a cover that can be opened and closed by tilting it forward (toward the front of the page) to protect the inside of the image forming apparatus 100. A user of the image forming apparatus 100 or a service technician performing maintenance can open the cover to access the inside of the image forming apparatus 100 and attach / detach the imaging unit 20 to / from a predetermined location within the image forming apparatus 100.

[0020] The image forming unit 20 is, for example, a process cartridge drum unit (hereinafter referred to as PCDU) that can be replaced depending on the life of the photosensitive drum 40.

[0021] The image forming apparatus 100 also includes a light beam scanning unit 21 above the image creating unit 20. The light beam scanning unit 21 irradiates the photosensitive drums 40 of each color with a light beam (laser light) for image formation, thereby forming an electrostatic latent image on the photosensitive drums 40 of each color according to image data.

[0022] The electrostatic latent image on the photosensitive drum 40 of each color is developed by a developing unit, and the developed toner images of each color are superimposed and primarily transferred onto the intermediate transfer belt 10. As a result, a color toner image is formed on the intermediate transfer belt 10. The toner image is carried on the intermediate transfer belt 10, which is an example of an image carrier, and moves along the direction in which the intermediate transfer belt 10 moves.

[0023] The image forming apparatus 100 also includes a secondary transfer unit 22 below the intermediate transfer belt 10. The secondary transfer unit 22 is arranged so that a secondary transfer belt 24, which is an endless belt, is stretched between two rollers 23 and pushes up the intermediate transfer belt 10 and presses it against a third support roller 16. The secondary transfer belt 24 can perform a second transfer of the toner image formed on the intermediate transfer belt 10 onto a sheet of paper.

[0024] Furthermore, image forming apparatus 100 is provided with a fixing unit 25 on the side of the secondary transfer unit. Fixing unit 25 fixes the toner image, which has been secondarily transferred onto the paper and has been conveyed thereto. Fixing unit 25 includes fixing belt 26, which is an endless belt, a heating roller, and a pressure roller 27, and can fix the toner image transferred onto the surface of the paper to the paper by the heat and pressure of fixing belt 26 and pressure roller 27.

[0025] In addition, the image forming apparatus 100 is provided with a sheet inversion unit 28 below the secondary transfer unit 22 and the fixing unit 25, which inverts the paper and sends it out so that an image can be formed on the back side of the paper immediately after an image has been formed on the front side.

[0026] Next, a series of steps for forming an image on a sheet in image forming apparatus 100 will be described.

[0027] When a "copy" start button on an operation unit (not shown) is pressed, image forming apparatus 100 causes ADF (Auto Document Feeder) 400, which is an automatic document transport unit, to transport the document onto contact glass 32 if the document is placed on document feed tray 30 of ADF 400. On the other hand, if no document is placed on document feed tray 30, image forming apparatus 100 drives image reading unit 300, which includes first carriage 33 and second carriage 34, to read a document manually placed on contact glass 32.

[0028] In the image reading unit 300, a light source included in the first carriage 33 irradiates light onto the contact glass 32. The light reflected from the document surface is reflected by a first mirror included in the first carriage 33 toward the second carriage 34, and is then reflected by a mirror included in the second carriage 34. The light reflected from the document surface is then imaged by an imaging lens 35 on the imaging surface of a CCD (Charge Coupled Device) 36, which is a reading sensor. The CCD 36 captures an image of the document surface, and image data for each of the colors Y, M, C, and BK is generated based on the image signal captured by the CCD 36.

[0029] In addition, when the "Print" start button is pressed, when an instruction to form an image is received from an external device such as a PC (Personal Computer), or when an instruction to output a FAX (Facsimile) is received, the image forming device 100 starts rotating the intermediate transfer belt 10 and prepares each unit of the image forming section 20 for image formation.

[0030] The image forming apparatus 100 then starts the image forming process for each color. A laser beam modulated based on image data for each color is irradiated onto the photosensitive drum 40 for each color, forming an electrostatic latent image. The electrostatic latent images are then developed into toner images of each color, which are then superimposed on the intermediate transfer belt 10 to form a single image.

[0031] Thereafter, the paper is fed into secondary transfer unit 22 at the same time that the leading edge of the toner image on intermediate transfer belt 10 enters secondary transfer unit 22. Then, secondary transfer unit 22 performs secondarily transferring the toner image on intermediate transfer belt 10 onto the paper. The paper onto which the toner image has been secondarily transferred is fed into fixing unit 25, where the toner image is fixed onto the paper.

[0032] Here, the feeding of paper to the secondary transfer position will be described. When one of paper feed rollers 42 of paper feed table 200 is driven to rotate, the paper is fed from one of paper feed trays 44 provided in multiple stages in paper feed unit 43. Then, a single sheet is separated by separation roller 45, enters conveyance roller unit 46, and is conveyed by conveyance roller 47. After that, the paper is guided to conveyance roller unit 48 in image forming apparatus 100, abuts against registration roller 49 of conveyance roller unit 48, is temporarily stopped, and then, as described above, is sent toward secondary transfer unit 22 in accordance with the timing of secondary transfer.

[0033] The user can also feed paper by inserting it into manual feed tray 51. When the user inserts paper into manual feed tray 51, image forming apparatus 100 rotates paper feed roller 50 to separate one sheet of paper from manual feed tray 51 and pull it into manual paper feed path 53. Then, as in the case described above, the paper is abutted against registration roller 49, stopped temporarily, and then sent to secondary transfer unit 22 in accordance with the timing of the secondary transfer described above.

[0034] The paper that has been fixed by the fixing unit 25 and discharged is guided by a switching claw 55 to discharge rollers 56, discharged by the discharge rollers 56, and stacked on a paper discharge tray 57. Alternatively, the paper is guided by the switching claw 55 to the sheet inversion unit 28, inverted by the sheet inversion unit 28, and led to the secondary transfer position again. Thereafter, an image is also formed on the back side of the paper, and the paper is discharged by the discharge rollers 56 onto the paper discharge tray 57.

[0035] On the other hand, residual toner remaining on the intermediate transfer belt 10 after the image transfer is removed by an intermediate transfer body cleaning unit 17, and the intermediate transfer belt 10 is prepared for next image formation.

[0036] In this way, the image forming apparatus 100 can form a color image on paper.

[0037] Fig. 2 is a perspective view showing a state in which the front cover 102 of the image forming apparatus 100 of this embodiment is open. As shown in Fig. 2, the front cover 102 is provided on the housing 101 of the image forming apparatus 100 of this embodiment. When the front cover 102 is open, bottle covers 140a to 140d that open and close the attachment / detachment openings of the four toner bottles 130a to 130d are provided on the side of the housing 101.

[0038] The front cover 102 has a mechanism for opening and closing the front cover 102. The front cover 102 is in an open state when, for example, the toner bottles 130a to 130d are attached or detached.

[0039] When the front cover 102 is in the closed state, it covers the bottle covers 140a to 140d and prevents the bottle covers 140a to 140d from opening.

[0040] A push sensor 104 is provided on the side of the housing 101. The push sensor 104 is an example of a detector that detects whether the front cover 102 is closed (restricted state) or open (unrestricted state). For example, when the front cover 102 is closed, the push sensor 104 is pressed, and when the front cover 102 is open, the push sensor 104 is pulled back. In other words, whether the front cover 102 is closed or not can be detected based on whether the push sensor 104 is pressed or not. Note that in this embodiment, the detector is not limited to the push sensor 104, and an open / close sensor or the like may be used.

[0041] 3 is an explanatory diagram showing a state in which the front cover 102 of the image forming apparatus 100 according to this embodiment is open and the corresponding bottle covers 140d and 140c are also open. As shown in FIG. 3, inside the bottle covers 140d and 140c, a toner bottle storage section (an example of a storage mechanism) 103 for storing the toner bottles 130a to 130d (replacement members) is provided.

[0042] The toner bottles 130a to 130d housed in the toner bottle housing section (an example of a housing mechanism) 103 are provided at their attachment / detachment openings with bottle covers (opening / closing members) 140a to 140d.

[0043] When toner bottles 130a to 130d are stored in toner bottle storage section 103 (moved in the direction of arrow Q), the shutter member of the toner bottle (not shown) moves in conjunction with the storing operation, opening the toner discharge port, connecting the supply port and the discharge port, and supplying toner into the main body.

[0044] The toner bottles 130a to 130d are, for example, cylindrical bottles, but may be of any shape.

[0045] By opening the front cover 102 of the image forming device 100 and opening the corresponding bottle covers 140a to 140d, each toner bottle 130a to 130d can be attached or detached from the toner bottle storage section 103 for each color provided inside the housing 101 in the direction of arrow Q of the image forming device 100 or in the direction opposite to arrow Q.

[0046] 4 is a perspective view showing the bottle cover 140a according to this embodiment in an open state. The bottle cover 140a according to this embodiment is provided so as to be rotatable about an opening / closing shaft 141. The bottle cover 140a is biased by a spring in the rotation direction corresponding to the opening direction. A hook 142 is provided on the bottle cover 140a, and a latch 151 is provided near the toner bottle storage section 103. The hook 142 and the latch 151 form part of a locking mechanism 150 according to this embodiment. Next, the locking mechanism 150 will be described.

[0047] Fig. 5(a) is an explanatory diagram of bottle cover 140a in a closed state, locked by locking mechanism 150, viewed from the X direction. Fig. 5(b) is an explanatory diagram of bottle cover 140a in an open state, with locking mechanism 150 in an unlocked state, viewed from the X direction. In the example shown in Fig. 5, bottle cover 140a corresponding to black toner bottle 130a will be described, but the other bottle covers 140b to 140d have the same configuration, so their description will be omitted.

[0048] The locking mechanism 150 is a mechanism for locking the bottle covers 140a to 140d (examples of opening / closing members) in a closed state. For example, the locking mechanism 150 is placed in a locked state when a hook 142 provided on the bottle cover 140a engages with a latch 151 provided on the housing 101 of the image forming apparatus 100, and is placed in an unlocked state when this engagement is released. The latch 151 is pivotally supported around a shaft 151a so as to be rotatable, and is biased by a spring 151b in the direction of arrow A in FIGS. 5(a) and 5(b) (the direction in which the latch 151 engages with the hook 142).

[0049] The latch 151 engages with a link 152 at the end opposite to the tip that engages with the hook 142 .

[0050] Link 152 is configured to be movable in the direction of arrow B in Fig. 5(a). When link 152 moves to the position shown in Fig. 5(b), latch 151 rotates in conjunction with the movement of link 152 against the biasing force of spring 151b in a direction in which the engagement with hook 142 is released, and locking mechanism 150 enters an unlocked state.

[0051] On the other hand, when the link 152 moves to the position shown in FIG. 5(a), the latch 151 rotates in the direction of engaging with the hook 142 due to the biasing force of the spring 151b, and the locking mechanism 150 enters the locked state.

[0052] A link spring 153 is attached to the link 152, which biases the link 152 in a direction in which the latch 151 disengages from the hook 142 against the biasing force of the spring 151b (in a direction in which the link 152 moves to the position shown in Figure 5(a)).

[0053] A solenoid 154 is also connected to the link 152, which moves the link 152 in a direction that moves the link 152 to the position shown in Fig. 5(b) against the biasing force of the link spring 153. The operation of the solenoid 154 is controlled by a drive control unit 155, which will be described later. The drive control unit 155 switches whether or not to supply power to the solenoid 154.

[0054] When power is supplied to the solenoid 154, the solenoid 154 is energized and turns ON. This causes the link 152 to move in a direction toward the position shown in Fig. 5(b) against the biasing force of the link spring 153. As a result, in conjunction with this movement of the link 152, the latch 151 rotates against the biasing force of the spring 151b in a direction to release the engagement with the hook 142, and the locking mechanism 150 enters an unlocked state.

[0055] When the power supply to the solenoid 154 is stopped, the solenoid 154 is turned off. As a result, the link 152 moves in the direction of moving to the position shown in Figure 5(a) due to the biasing force of the link spring 153. As a result, the latch 151 rotates in the direction of engaging with the hook 142 due to the biasing force of the spring 151b, and the locking mechanism 150 is put into the locked state.

[0056] In this way, the lock mechanism 150 according to this embodiment switches between a locked state and an unlocked state depending on the operation of the solenoid 154 (the state of power supply).

[0057] With the above-described configuration, when the toner bottles 130a-130d are installed and the bottle covers 140a-140d are closed, the locking mechanism 150 is locked. The user cannot remove the toner bottles 130a-130d until the locking mechanism 150 is released. This configuration prevents the toner bottles with remaining toner from being replaced with new toner bottles, thereby preventing the generation of wasted toner.

[0058] Next, a control unit 156 that controls each component of the image forming apparatus 100 according to this embodiment will be described. Fig. 6 is a diagram illustrating the configuration of the control unit 156 according to this embodiment. The control unit 156 shown in Fig. 6 is connected to components included in each load 165 in the image forming apparatus 100 via signal lines or the like. Each load 165 in the image forming apparatus 100 includes, for example, a solenoid 154, a push sensor 104, and a remaining amount detection sensor 165a.

[0059] The remaining amount detection sensor 165a detects the remaining amount of toner stored in the toner bottles 130a to 130d. The remaining amount detection sensor 165a may be any known sensor as long as it can detect the remaining amount of toner.

[0060] Furthermore, the control unit 156 is connected to an external device 170 so as to be able to communicate with the external device 170. The external device 170 includes, for example, an operation unit and a display device. For example, the control unit 156 can display a screen based on information received from each load 165 on the display device.

[0061] The control unit 156 is composed of a CPU (Central Processing Unit) 161, a RAM (Random Access Memory) 162, a ROM (Read Only Memory) 163, and an IO control unit 164. The CPU 161, RAM 162, ROM 163, and IO control unit 164 are interconnected via a bus.

[0062] For example, CPU 161 controls image forming apparatus 100 in accordance with various programs stored in ROM 163. CPU 161 can control image forming apparatus 100 in accordance with control commands input from external device 170. The control commands input from external device 170 include, for example, operation information for an operation unit provided in external device 170.

[0063] The RAM 162 is a readable and writable memory, and is used as a work area when the CPU 161 executes various programs.

[0064] The ROM 163 is a non-volatile storage medium that stores various programs executed by the CPU 161 and also stores a threshold value storage unit 163a.

[0065] The threshold value storage unit 163a stores a threshold value T related to the remaining amount of toner. Specific processing using the threshold value T will be described later. The threshold value T stored in the threshold value storage unit 163a can be changed by the CPU 161 in response to operation information from the external device 170, for example.

[0066] The IO control unit 164 is configured to transmit and receive information to and from each load 165, and is configured as, for example, an ASIC. The IO control unit 164 writes information about each load 165 to a registry, allowing the CPU 161 to refer to the information. This allows the CPU 161 to refer to, for example, the detection results of the push sensor 104 and the detection results of the remaining amount detection sensor 165a.

[0067] The drive control unit 155 is configured to control the operation of the solenoid 154 and detect failure of the solenoid 154 .

[0068] If a malfunction occurs in the locking mechanism 150 including the solenoid 154 of this embodiment, the bottle cover 140a that opens and closes the attachment / detachment opening of the toner bottle 130a (the attachment / detachment opening of the toner bottle storage unit 103) cannot be opened. As a result, the toner bottle 130a cannot be replaced until the locking mechanism 150 is repaired or replaced.

[0069] Conventionally, when it is time to replace toner bottle 130a (when toner bottle 130a becomes empty), and a user attempts to unlock locking mechanism 150 to replace toner bottle 130a, the user only realizes that locking mechanism 150 has broken down if the user is unable to unlock the locked state. Arrangements for replacement parts may then be made only after the user has recognized the malfunction. In this case, image formation by image forming apparatus 100 cannot be performed until repairs to locking mechanism 150 are completed, resulting in a long downtime.

[0070] Therefore, in this embodiment, a failure detection circuit for the solenoid 154 is provided in the drive control unit 155 that controls the drive of the solenoid 154 as a failure detection unit that detects a failure of the lock mechanism 150. The failure detection result by the drive control unit 155 is notified to the CPU 161 via the registry.

[0071] Then, CPU 161 displays a message indicating that a malfunction has occurred on a display device in external device 170. This allows, for example, a maintenance person to recognize the malfunction of locking mechanism 150 (malfunction of solenoid 154) before it is time to replace toner bottle 130a (when toner bottle 130a becomes empty). Therefore, preparations for repair or replacement of locking mechanism 150 can be started before it is time to replace toner bottle 130a (while toner remains in toner bottle 130a). Therefore, according to this embodiment, even if a malfunction occurs in locking mechanism 150, it is possible to prevent a state in which empty toner bottle 130a cannot be replaced from lasting for a long time.

[0072] 7 is an explanatory diagram showing an example of the configuration of the drive control unit 155 including a failure detection circuit for the solenoid 154 in this embodiment. As shown in FIG. 7, the solenoid 154 is connected to the drive control unit 155 via a connector 158.

[0073] A power supply voltage (+24 V) is connected to a first terminal of the solenoid 154 via a connector 158. A switching element Q1, which may be a field effect transistor (FET), is connected to a second terminal of the solenoid 154, and the power supply voltage (+24 V) is also connected to the second terminal via a diode D1. A controller 155 a is connected to the switching element Q1 via electrical resistance elements R1 and R2.

[0074] When the controller 155a turns on the switching element Q1, the voltage at the second terminal of the solenoid 154 is dropped to the ground voltage, which causes a current to flow through the solenoid 154 due to the power supply voltage (+24V) connected to the first terminal of the solenoid 154, turning the solenoid 154 on (a state in which power is being supplied).

[0075] On the other hand, when the controller 155a turns off the switching element Q1, the voltage at the second terminal of the solenoid 154 becomes the same as the voltage at the first terminal of the solenoid 154 due to the power supply voltage (+24 V) connected via the diode D1. As a result, no current flows through the solenoid 154, and the solenoid 154 turns off (a state in which no power is being supplied).

[0076] In this embodiment, two electrical resistance elements R3 and R4 connected in series are connected to the second terminal of the solenoid 154. A voltage signal divided by these electrical resistance elements R3 and R4 is input to the controller 155a. In this embodiment, this voltage signal is used as a failure detection signal for the lock mechanism 150 (solenoid 154).

[0077] The drive control unit 155 according to this embodiment detects a failure in which the solenoid 154 does not turn OFF and a failure in which the solenoid 154 does not turn ON.

[0078] A failure in which the solenoid 154 does not turn OFF (locked state failure) is a failure in which the locking mechanism 150 does not switch to the locked state, in other words, the locked state cannot be maintained. On the other hand, a failure in which the solenoid 154 does not turn ON is a failure in which the locking mechanism 150 does not switch to the unlocked state. These failures occur, for example, due to a broken wire in the solenoid 154 winding, the solenoid 154 coming off the connector (harness) 58, or a broken wire in the connector (harness) 58.

[0079] First, a control for detecting a failure in which the solenoid 154 does not turn off (a locked state failure) will be described.

[0080] The controller 155a controls the switching element Q1 to turn off in order to turn off the solenoid 154. If no failure that prevents the solenoid 154 from turning off occurs, the solenoid 154 turns off normally. In this case, the voltage at the second terminal of the solenoid 154 is the power supply voltage (+24V), and the failure detection signal input to the controller 155a becomes "High."

[0081] If a failure occurs in which the solenoid 154 does not turn off (a locked state failure), the second terminal of the solenoid 154 will be electrically floating. Therefore, even if the controller 155a performs control to turn off the switching element Q1 in order to turn off the solenoid 154, the voltage of the second terminal of the solenoid 154 will be maintained at the voltage immediately before the switching element Q1 was turned off, i.e., the ground voltage. As a result, the failure detection signal input to the controller 155a will be "Low."

[0082] Furthermore, a failure in which the solenoid 154 does not turn off (locked state failure) can also occur, for example, due to a failure of the switching element Q1 of the drive control unit 155. For example, if the switching element Q1 fails, even if the controller 155a performs control to turn off the switching element Q1 in order to turn off the solenoid 154, the switching element Q1 remains in the ON state. Therefore, the voltage at the second terminal of the solenoid 154 is maintained at the ground voltage. As a result, the failure detection signal input to the controller 155a becomes "Low."

[0083] In this way, the drive control unit 155 of this embodiment detects a failure in which the solenoid 154 does not turn OFF (non-locked state failure) when the solenoid 154 is turned OFF (no power supply), in other words, a failure as to whether or not the locking mechanism 150 switches to the locked state.

[0084] Next, a control for detecting a failure in which the solenoid 154 does not turn on (unlocked state failure) will be described.

[0085] First, the controller 155a controls the switching element Q1 to turn on in order to turn on the solenoid 154. If a failure that prevents the solenoid 154 from turning on (an unlocked state failure) does not occur, the solenoid 154 turns on normally. In this case, the voltage at the second terminal of the solenoid 154 is dropped to the ground voltage, and the failure detection signal input to the controller 155a becomes "Low."

[0086] If a failure occurs in which the solenoid 154 does not turn ON (an unlocked state failure), the second terminal of the solenoid 154 will be electrically floating. Therefore, even if the controller 155a performs control to turn ON the switching element Q1 in order to turn ON the solenoid 154, the voltage of the second terminal of the solenoid 154 will be maintained at the voltage immediately before the switching element Q1 was turned ON, i.e., the power supply voltage (+24V). As a result, the failure detection signal input to the controller 155a will be "High."

[0087] Furthermore, a failure in which the solenoid 154 does not turn ON (unlocked state failure) can also occur, for example, due to a failure of the switching element Q1 of the drive control unit 155. For example, in the case of a failure of the switching element Q1, even if the controller 155a performs control to turn ON the switching element Q1 in order to turn ON the solenoid 154, the switching element Q1 remains OFF. In this case, the voltage at the second terminal of the solenoid 154 is maintained at the power supply voltage (+24V), and therefore the failure detection signal input to the controller 155a becomes "High."

[0088] In this way, the drive control unit 155 of this embodiment turns on (supplies power to) the solenoid 154 and performs failure detection for a failure in which the solenoid 154 does not turn on (non-locked state failure), in other words, whether or not the locking mechanism 150 switches to the unlocked state.

[0089] In this embodiment, when a failure (unlocked state failure) in which the solenoid 154 does not turn ON is detected, the controller 155a controls to turn ON the solenoid 154. When the solenoid 154 is normal, the solenoid 154 turns ON, and in conjunction with the locking mechanism 150 being released from the lock, the biasing force of the spring rotates the bottle cover 140a in the opening direction, thereby opening the bottle cover 140a.

[0090] As described above, when the front cover 102 is in the closed state, the front cover 102 presses the bottle cover 140a in the closing direction, so the bottle cover 140a cannot be opened.

[0091] On the other hand, when the front cover 102 is open, if the drive control unit 155 detects a malfunction in which the solenoid 154 does not turn on (a malfunction in an unlocked state), the bottle cover 140a will open if the solenoid 154 is normal. In this case, the user will have to close the bottle cover 140a every time the malfunction is detected.

[0092] On the other hand, when the drive control unit 155 detects a failure in which the solenoid 154 does not turn OFF (locked state failure), the solenoid 154 is turned OFF, so that even if the front cover 102 is open, the bottle cover 140a will not open.

[0093] Therefore, the control unit 156 in this embodiment instructs the drive control unit 155 to detect a failure in which the solenoid 154 does not turn OFF at different times from the detection of a failure in which the solenoid 154 does not turn ON.

[0094] Specifically, CPU 161 of control unit 156 determines whether it is time to detect a failure. If CPU 161 of control unit 156 determines that it is time to detect a failure, it instructs drive control unit 155 to execute failure detection.

[0095] Table 1 below shows the correspondence between the state of the front cover 102 and the execution of fault detection in this embodiment.

[0096] [Table 1]

[0097] As shown in Table 1, when the push sensor 104 detects that the front cover 102 is open, the control unit 156 does not instruct the execution of "failure detection when the solenoid is ON" in case of a failure in which the solenoid 154 does not turn ON (non-locked state failure).

[0098] When the control unit 156 determines that it is time to detect a fault, if the push sensor 104 detects that the front cover 102 is closed, it instructs the execution of "fault detection when the solenoid is ON" to detect a fault where the solenoid 154 does not turn ON (non-locked state fault).

[0099] On the other hand, when the control unit 156 determines that it is time to detect a malfunction, it issues an instruction to execute malfunction detection when the solenoid 154 is not turned off (locked state malfunction), i.e., when the solenoid is off, regardless of whether the push sensor 104 detects that the front cover 102 is open.

[0100] When the drive control unit 155 executes the failure detection, the controller 155a of the drive control unit 155 writes the input failure detection signal into the registry, thereby enabling the CPU 161 to recognize the execution result of the failure detection.

[0101] Furthermore, in this embodiment, the timing of fault detection is different for a fault in which the solenoid 154 does not turn ON (unlocked state fault) and a fault in which the solenoid 154 does not turn OFF (locked state fault) under conditions other than the opening and closing of the front cover 102.

[0102] This is based on the power consumption when detecting a failure in which the solenoid 154 does not turn on (unlocked state failure).

[0103] When detecting a failure in which the solenoid 154 does not turn on (unlocked state failure), it is necessary to supply power to the solenoid 154. In other words, if detection of a failure in which the solenoid 154 does not turn on (unlocked state failure) is performed frequently, power consumption increases.

[0104] On the other hand, a malfunction of the locking mechanism 150 does not affect image formation by the image forming apparatus 100. Therefore, repairs to the malfunction of the locking mechanism 150 may be performed before the toner bottles 130a to 130d are replaced.

[0105] In other words, if there is a large amount of toner remaining in the toner bottles 130a to 130d, there is still time until the replacement period for the toner bottles 130a to 130d, so even if a malfunction is detected in the locking mechanism 150, there is no need to rush to repair the malfunction or replace the part. In other words, it is sufficient to detect a malfunction in the locking mechanism 150 before the replacement period for the toner bottles 130a to 130d.

[0106] Therefore, the control unit 156 according to this embodiment detects a failure in which the solenoid 154 does not turn ON (unlocked state failure) only when the amount of toner remaining in the toner bottles 130a to 130d is equal to or less than the threshold value T. On the other hand, because detection of a failure in which the solenoid 154 does not turn OFF (locked state failure) does not consume power, it is performed regardless of the amount of toner remaining in the toner bottles 130a to 130d.

[0107] Specifically, CPU 161 of control unit 156 according to this embodiment refers to threshold value T in threshold value storage unit 163a. ​​When push sensor 104 detects that front cover (an example of a cover member) 102 is closed and when it is determined that the remaining amount of toner contained in toner bottles 130a to 130d is less than threshold value T, CPU 161 of control unit 156 instructs drive control unit 155 to execute detection of a malfunction in which solenoid 154 does not turn ON (non-locked state malfunction). Then, drive control unit 155 executes detection of a malfunction in which solenoid 154 does not turn ON (non-locked state malfunction), in other words, malfunction detection of whether lock mechanism 150 can be switched to an unlocked state.

[0108] The threshold value T stored in the threshold value storage unit 163a according to this embodiment may be determined depending on the implementation, and may be set to, for example, 50% of the initial toner amount.

[0109] Furthermore, in this embodiment, the threshold value T may be changed depending on the usage status of the image forming apparatus 100. In other words, the degree of toner depletion in the toner bottles 130a to 130d differs depending on the usage status of the user. For example, during busy periods, the toner bottles 130a to 130d tend to deplete significantly, so it may be better to detect a malfunction early and repair the lock mechanism 150 when the user is not using the device.

[0110] Therefore, in this embodiment, the CPU 161 is able to change the threshold value T stored in the threshold value storage unit 163a in accordance with operation information received from an operation unit included in the external device 170.

[0111] 8 is a flowchart showing a first execution procedure for detecting a malfunction in which solenoid 154 does not turn ON (unlocked state malfunction), which is performed in image forming apparatus 100 according to this embodiment. In the example shown in FIG. 8, a case where a malfunction is detected for toner bottle 130a will be described, but similar processing is performed for toner bottles 130b to 130d, so a description thereof will be omitted.

[0112] The CPU 161 of the control unit 156 acquires the detection result of the remaining amount of toner contained in the toner bottle 130a from the remaining amount detection sensor 165a via the IO control unit 164 (S1801).

[0113] Next, CPU 161 determines whether the remaining amount of toner contained in toner bottle 130a is equal to or less than threshold value T (S1802). If CPU 161 determines that the remaining amount of toner is greater than threshold value T (S1802: NO), CPU 161 performs the process again from S1801 after a predetermined time has elapsed.

[0114] On the other hand, if CPU 161 determines that the remaining amount of toner is equal to or less than threshold value T (S1802: YES), CPU 161 determines whether or not it is the timing when image forming apparatus 100 was powered on (S1803). If CPU 161 determines that it is not the timing when image forming apparatus 100 was powered on (S1803: NO), CPU 161 performs the process again from S1803.

[0115] On the other hand, if the CPU 161 determines that the image forming apparatus 100 has been powered on (S1803: YES), it determines whether the front cover 102 is closed or not (S1804) based on a signal from the push sensor 104. If it determines that the front cover is not closed (open) (S1804: NO), it performs the process again from S1803.

[0116] On the other hand, if the CPU 161 determines that the front cover 102 is closed (S1804: YES), it instructs the drive control unit 155 to perform detection of a failure in which the solenoid 154 does not turn ON (non-locked state failure), and the drive control unit 155 performs detection of a failure in which the solenoid 154 does not turn ON (non-locked state failure) (S1805).

[0117] In the above-described processing procedure, failure detection of the solenoid 154 is not performed for the bottle covers 140a to 140d of the colors having a sufficient amount of remaining toner, so that power consumption can be reduced.

[0118] In this embodiment, the execution procedure for detecting a failure in which the solenoid 154 does not turn ON (unlocked state failure) is not limited to the procedure shown in FIG. 8, and other execution procedures may be used.

[0119] 9 is a flowchart showing a second execution procedure for detecting a malfunction in which solenoid 154 does not turn ON (unlocked malfunction), which is performed in image forming apparatus 100 according to this embodiment. In the example shown in FIG. 9, a case where a malfunction is detected for toner bottle 130a will be described, but similar processing is also performed for toner bottles 130b to 130d, and therefore a description thereof will be omitted.

[0120] The CPU 161 of the control unit 156 obtains the count result of the number of pixels output since the toner bottle 130a was replaced from a pixel counter (not shown) provided in the image forming apparatus 100 via the IO control unit 164 (S1901).

[0121] The CPU 161 calculates the remaining amount of toner contained in the toner bottle 130a from the acquired count result of the number of pixels (S1902).

[0122] Next, CPU 161 determines whether the remaining amount of toner contained in toner bottle 130a is equal to or less than threshold value T (S1903). If CPU 161 determines that the remaining amount of toner is greater than threshold value T (S1903: NO), CPU 161 performs the process again from S1901 after a predetermined time has elapsed.

[0123] On the other hand, if CPU 161 determines that the remaining amount of toner is equal to or less than threshold value T (S1903: YES), CPU 161 determines whether or not it is the timing when image forming apparatus 100 was turned on (S1904). If CPU 161 determines that it is not the timing when image forming apparatus 100 was turned on (S1904: NO), CPU 161 performs the process again from S1904.

[0124] On the other hand, if the CPU 161 determines that the image forming apparatus 100 has been powered on (S1904: YES), it determines whether the front cover 102 is closed or not (S1905) based on a signal from the push sensor 104. If it determines that the front cover is not closed (open) (S1905: NO), it performs the process again from S1904.

[0125] On the other hand, if the CPU 161 determines that the front cover 102 is closed (S1905: YES), it instructs the drive control unit 155 to perform detection of a failure in which the solenoid 154 does not turn ON (non-locked state failure), and the drive control unit 155 performs detection of a failure in which the solenoid 154 does not turn ON (non-locked state failure) (S1906).

[0126] 9, the remaining toner amount is calculated based on the count of the number of pixels, so even if the remaining toner amount cannot be directly detected without the remaining amount detection sensor 165a, etc., it is possible to perform failure detection according to the remaining toner amount. Therefore, costs can be reduced by omitting the remaining amount detection sensor 165a, etc., and power consumption can be reduced because failure detection of the solenoid 154 is not performed for the bottle covers 140a to 140d of colors that are assumed to have sufficient remaining toner.

[0127] On the other hand, in the case of a fault in which the solenoid 154 does not turn off (locked state fault), there is no need to supply power to the solenoid 154, so there is no problem even if the detection is performed frequently. Furthermore, it is often preferable to be able to detect the fault itself early.

[0128] Therefore, the control unit 156 (an example of a failure detection unit) according to this embodiment instructs the drive control unit 155 to detect a failure (locked state failure) in which the solenoid 154 does not turn off when the power of the image forming apparatus 100 is turned on. Then, the drive control unit 155 detects a failure (locked state failure) in which the solenoid 154 does not turn off, in other words, detects whether the locking mechanism 150 is maintained in the locked state.

[0129] 10 is a flowchart showing a first execution procedure for detecting a malfunction in which solenoid 154 does not turn OFF (locked state malfunction), which is performed in image forming apparatus 100 according to this embodiment. In the example shown in FIG. 10, a case where a malfunction is detected for toner bottle 130a will be described, but similar processing is performed for toner bottles 130b to 130d, so a description thereof will be omitted.

[0130] The CPU 161 of the control unit 156 determines whether or not the image forming apparatus 100 has been powered on (S2001). If the CPU 161 determines that the image forming apparatus 100 has not been powered on (S2001: NO), the CPU 161 performs the process again from S2001.

[0131] On the other hand, if the CPU 161 determines that the power of the image forming apparatus 100 has been turned on (S2001: YES), it instructs the drive control unit 155 to perform detection of a failure in which the solenoid 154 does not turn off (locked state failure), and the drive control unit 155 performs detection of a failure in which the solenoid 154 does not turn off (locked state failure) (S2002).

[0132] In this embodiment, the execution procedure for detecting a failure in which the solenoid 154 does not turn off (locked state failure) is not limited to the procedure shown in FIG. 10, and other execution procedures may be used.

[0133] 11 is a flowchart showing a second execution procedure for detecting a malfunction in which solenoid 154 does not turn OFF (locked state malfunction), which is performed in image forming apparatus 100 according to this embodiment. In the example shown in FIG. 11, a case where a malfunction is detected for toner bottle 130a will be described, but similar processing is also performed for toner bottles 130b to 130d, and therefore a description thereof will be omitted.

[0134] The CPU 161 of the control unit 156 determines whether the image forming apparatus 100 was powered on or returned from an energy-saving state (S2101). If the CPU 161 determines that the image forming apparatus 100 was not powered on or returned from an energy-saving state (S2101: NO), the CPU 161 performs the process again from S2101.

[0135] On the other hand, if the CPU 161 determines that the image forming apparatus 100 has been powered on or has returned from an energy saving state (S2101: YES), it instructs the drive control unit 155 to detect a failure in which the solenoid 154 does not turn off (locked state failure), and the drive control unit 155 detects a failure in which the solenoid 154 does not turn off (locked state failure) (S2102).

[0136] In the processing procedure shown in FIG. 11, compared to the processing procedure shown in FIG. 10, detection of a failure in which the solenoid 154 does not turn off even when returning from the energy saving state (locked state failure) is performed, thereby enabling early detection of the failure.

[0137] In the present embodiment, the timing at which the control unit 156 performs the fault detection is, for example, the timing at which the image forming apparatus 100 is powered on. However, the present embodiment does not limit the timing at which the fault detection is performed, and other timings may also be used.

[0138] (Second embodiment) In the above-described embodiment, an example has been described in which a maintenance person checks the failure detection result via external device 170. However, the present invention is not limited to the method in which a maintenance person goes to the location where image forming apparatus 100 is installed and checks the failure detection result, as in the above-described embodiment.

[0139] Fig. 12 is a diagram illustrating an example of the configuration of a control unit 156 according to the second embodiment. The control unit 156 shown in Fig. 12 is connected to a remote access I / F 180. The control unit 156 is capable of communicating with a management center of the image forming apparatus 100 via the remote access I / F 180. Note that the configuration other than the remote access I / F 180 is the same as in the above-described embodiment, and therefore description thereof will be omitted.

[0140] In this embodiment, CPU 161 controls the sending and receiving of control commands from a management center (an example of a remote location) via remote access I / F 180, and CPU 161 controls the entire image forming apparatus 100 in accordance with the received control commands.

[0141] CPU 161 transmits the usage status of image forming apparatus 100 to the management center via remote access I / F 180. Therefore, the management center can recognize, for example, the amount of toner remaining in toner bottles 130b to 130d.

[0142] Furthermore, CPU 161 receives a control command for changing threshold value T from the management center via remote access I / F 180, and changes threshold value T based on the received control command. Therefore, in this embodiment, the management center can change threshold value T depending on the amount of toner remaining. In other words, maintenance personnel can change threshold value T without going to a location where image forming apparatus 100 is grounded.

[0143] Furthermore, CPU 161 transmits the failure detection result to the management center via remote access I / F 180. This allows the management center to recognize the failure state of image forming apparatus 100.

[0144] In the above-described embodiment, the replaceable parts are described as toner bottles 130a to 130d, but there are no particular limitations as long as they are replaceable parts provided in the image forming apparatus. Therefore, the replaceable parts may be, for example, other consumable goods containers that store consumable goods (lubricants, developers, etc.) consumed in image formation, or containers such as waste toner containers that store waste materials generated in image formation. They may also be replaceable units such as photoconductors, development units, and fixing units.

[0145] In the image forming apparatus 100 according to the embodiment described above, the above-described configuration enables failure detection to be performed to determine whether the locking mechanism 150 can be switched to the unlocked state when the remaining amount of toner is low, thereby reducing the downtime. Furthermore, the power consumption of the image forming apparatus 100 can be reduced.

[0146] Although several forms for carrying out the present invention have been described above, the present invention is not limited to these embodiments, and various modifications and substitutions can be made within the scope that does not deviate from the gist of the present invention. [Explanation of symbols]

[0147] 100 Image forming device 102 Front cover 103 Toner bottle storage compartment 104 Push Sensor 130a~130d Toner bottle 140a~140d Bottle Cover 150 Locking mechanism 154 Solenoid 156 Control Unit 161 CPU 162 RAM 163 ROM 163a Threshold memory unit 164 IO control unit 165 each load 165a Remaining amount detection sensor 170 External device 180 Remote Access I / F [Prior art documents] [Patent documents]

[0148] [Patent Document 1] JP 2020-190694 A

Claims

1. a replacement member storage mechanism that stores toner for image formation; an opening / closing member provided at an access opening for the replacement member housed in the housing mechanism; a locking mechanism for locking the opening / closing member in a closed state; a cover member that is openable and closable and that covers the openable / closable member when in a closed state and prevents the openable / closable member from being opened; a detection unit that detects whether the cover member is in a closed state; a failure detection unit that performs failure detection to determine whether the locking mechanism can be switched to an unlocked state when it is detected that the cover member is in a closed state and when it is determined that the amount of toner contained in the replaceable member is less than a predetermined threshold; and An image forming apparatus comprising:

2. the failure detection unit performs failure detection to determine whether the locking mechanism is maintained in a locked state when the image forming apparatus is powered on or when the image forming apparatus returns from an energy saving state; The image forming apparatus according to claim 1 .

3. The predetermined threshold value is changeable based on an operation or a remote input. The image forming apparatus according to claim 1 .

4. The locking mechanism is switched between a locked state and an unlocked state by the operation of a solenoid, the failure detection unit supplies power to the solenoid and performs failure detection to determine whether the locking mechanism switches to an unlocked state. The image forming apparatus according to claim 1 .

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