Image forming apparatus and program

Abstract

The present invention provides an image forming apparatus and program capable of detecting the state of a filter. [Solution] The image forming apparatus according to the embodiment includes an image forming station, a filter, a sensor, and a processor. The image forming station performs image forming using toner. The filter collects toner scattered from the image forming station. The sensor detects the weight of the filter, including the toner collected by the filter. The processor detects information indicating an abnormality in the amount of toner collected by the filter if the weight detected by the sensor exceeds a predetermined threshold before a predetermined maintenance period is reached.

Description

Technical Field

[0001] Embodiments of the present invention relate to an image forming apparatus and a program.

Background Art

[0002] An image forming apparatus placed in a workplace forms a visible image corresponding to image data on a sheet of paper. Conventional image forming apparatuses include a mechanism that creates a flow of air by a fan motor and collects foreign substances by a filter provided in the air flow path. An electrophotographic image forming apparatus has a mechanism for collecting toner scattered outside a developing unit together with air, a mechanism for supplying outside air to a specific part, and a mechanism for sucking air from a specific part.

[0003] An electrophotographic image forming apparatus forms a visible image (toner image) by attaching toner to an electrostatic latent image formed by light irradiated onto a charged photoreceptor drum. Some electrophotographic image forming apparatuses are provided with a toner suction unit for collecting toner scattered between a developing unit and a photoreceptor drum. The toner suction unit is provided with a fan motor and a toner filter that collects toner contained in the air sucked by the fan motor. In a conventional image forming apparatus, the toner filter is replaced in regular maintenance performed according to the printing volume or the like.

[0004] However, if the toner suction unit sucks more toner than the assumed amount, the toner filter may become clogged before reaching regular maintenance. When the toner filter becomes clogged, it becomes difficult for toner to be drawn into the toner suction unit, and there is a high possibility that the toner scatters inside the machine. When toner scatters inside the machine, not only does it take time to clean, but there is also a problem that it causes malfunction of each part. In order to solve such problems, there is a demand for an image forming apparatus that can detect the state of a filter such as clogging.

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Application Publication No. 5-137929 [Overview of the project] [Problems that the invention aims to solve]

[0006] The problem that the embodiments of the present invention aim to solve is to provide an image forming apparatus and program capable of detecting the state of a filter. [Means for solving the problem]

[0007] According to one embodiment, the image forming apparatus includes an image forming station, a filter, a sensor, and a processor. The image forming station performs image formation using toner. The filter collects toner scattered from the image forming station. The sensor detects the weight of the filter, including the toner collected by the filter. The processor detects information indicating an abnormality in the amount of toner collected by the filter if the weight detected by the sensor exceeds a predetermined threshold before a predetermined maintenance period is reached. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a schematic diagram of a printing system including an image forming apparatus according to an embodiment. [Figure 2] Figure 2 is a schematic cross-sectional view showing an example of the configuration of an image forming apparatus according to an embodiment. [Figure 3] Figure 3 is a block diagram showing an example of the configuration of a control system in an image forming apparatus according to an embodiment. [Figure 4] Figure 4 is a cross-sectional view showing an example of the configuration of an electrophotographic image forming station in an image forming apparatus according to an embodiment. [Figure 5] Figure 5 is an external view showing an example of the configuration of a toner suction unit in an image forming apparatus according to the embodiment. [Figure 6]Figure 6 is a cross-sectional view showing an example of the configuration within a toner suction unit in an image forming apparatus according to an embodiment. [Figure 7] Figure 7 shows an example of the configuration of the connection path between the toner suction unit and the recovery unit in the developer of each image forming station in the image forming apparatus according to the embodiment. [Figure 8] Figure 8 shows an example of the configuration of the connection path between the toner suction unit and the recovery unit in the developer of each image forming station in the image forming apparatus according to the embodiment. [Figure 9] Figure 9 shows an example of a factor that causes an unexpectedly large amount of toner to be scattered from the developer in the image forming apparatus according to this embodiment. [Figure 10] Figure 10 shows a first example of the configuration of a weight detection unit that detects the weight of toner collected by a toner filter in an image forming apparatus according to the embodiment. [Figure 11] Figure 11 shows a second example of the configuration of a weight detection unit that detects the weight of toner collected by a toner filter in an image forming apparatus according to the embodiment. [Figure 12] Figure 12 is a flowchart illustrating a state detection process in which an image forming apparatus according to an embodiment detects the state of a toner filter using a weight detection unit of the first or second configuration example. [Figure 13] Figure 13 shows a third example of the configuration of a weight detection unit that detects the weight of toner collected by a toner filter in an image forming apparatus according to the embodiment. [Figure 14] Figure 14 is a flowchart illustrating a state detection process in which an image forming apparatus according to an embodiment detects the state of a toner filter using a detection unit as a weight detection unit of the third configuration example. [Modes for carrying out the invention]

[0009] The image forming apparatus according to this embodiment will be described below with reference to the drawings. Note that the scale of each part has been appropriately changed in the drawings used to describe the following embodiments. Also, for illustrative purposes, some components have been omitted in the drawings used to describe the following embodiments.

[0010] Figure 1 is a schematic diagram of a printing system (image forming system) including multiple image forming apparatuses 100 according to the embodiment. The printing system including the image forming apparatuses 100 further comprises multiple user terminals 200, a server device 300, and a service technician terminal 400.

[0011] Each image forming apparatus 100 is located in a workplace and is connected to a user terminal 200 located in the same workplace, for example, via an internal network 500 such as a LAN (Local Area Network). This connection may be wired or wireless. The internal network 500 is also connected to an external network 600 such as the Internet. The server device 300 and the service technician terminal 400 are connected to the external network 600. The image forming apparatus 100 is connected to the server device 300 via the internal network 500 and the external network 600.

[0012] The user terminal 200 is an information processing device that instructs printing on any of the image forming apparatuses 100. The user terminal 200 is, for example, an information processing device such as a personal computer (PC), smartphone, tablet terminal, or digital camera. The user terminal 200 may be connected to the image forming apparatus 100 in a communicative manner via an external network 600 and an internal network 500. That is, the user terminal 200 may be located outside the workplace where the image forming apparatus 100 is located. The user terminal 200 may also be connected directly to the image forming apparatus 100 without going through the external network 600 and the internal network 500. In other words, the user terminal 200 may be locally connected to the image forming apparatus 100. When the user terminal 200 is locally connected to the image forming apparatus 100, it may be a wired connection or a wireless connection.

[0013] The server device 300 is a computer device that is directly operated by a management company that undertakes the maintenance and inspection of the image forming device 100 or is entrusted to a service provider. The server device 300 periodically or as necessary acquires the maintenance information of each image forming device 100. The maintenance information includes information indicating the operating status of the image forming device 100 (such as the number of prints, the size and type of the printed paper, etc.) and information indicating the status of each part (information indicating the status of the filter). The server device 300 may acquire notification data such as an alert transmitted from the image forming device 100.

[0014] Based on the acquired data, the server device 300 determines the necessity of inspection or repair (maintenance) of each image forming device 100. When there is an image forming device 100 that requires maintenance, the server device 300 transmits information identifying the image forming device 100 that requires maintenance to the service technician terminal 400. Thereby, the service technician can go to the maintenance of the image forming device 100 determined by the server device 300 to be in need of maintenance.

[0015] The server device 300 is an information processing device having a processor 3001, a memory 3002, a communication interface (I / F) 3003, etc. The processor 3001 is, for example, a CPU. The processor 3001 executes various processes by executing the programs stored in the memory 3002. The communication interface 3003 is an interface for communicating with each device via the network 600. The memory 3002 is composed of storage devices such as a ROM, a RAM, and a non-volatile memory. The memory 3002 includes a program memory that stores programs, a working memory that temporarily holds data, and a data memory that accumulates data.

[0016] In the server device 300, the memory 3002 has a storage area for storing a database that stores maintenance information and the like acquired from the image forming apparatus 100. The processor 3001 of the server device 300 stores information such as maintenance information acquired from the image forming apparatus 100 in the database of the memory 3002. The processor 3001 of the server device 300 determines the necessity of maintenance for each image forming apparatus based on the maintenance information of each image forming apparatus stored in the database.

[0017] The service technician terminal 400 is an information processing device such as a smartphone or a tablet terminal carried by a service technician who performs maintenance on the image forming apparatus 100. In FIG. 1, only one service technician terminal 400 is shown, but the printing system may include a plurality of service technician terminals 400. The service technician terminal 400 may be provided with a position detection function and transmit the position detected by the position detection function to the server device 300 as the position information of the service technician. The server device 300 can also assign an appropriate service technician to the image forming apparatus 100 that requires maintenance based on information such as the position information of each service technician and the availability of each service technician.

[0018] FIG. 2 is a cross-sectional view schematically showing a configuration example of the image forming apparatus 100 according to the embodiment. The image forming apparatus 100 according to the embodiment is assumed to be a digital multi-functional peripheral (MFP). In the configuration example shown in FIG. 2, the image forming apparatus 100 is a digital multi-functional peripheral having a scanner 1, a printer 2, an operation panel 4, and a system control unit 5.

[0019] Scanner 1 is a device that reads an image from a document and converts it into image data. Scanner 1 is composed of, for example, a CCD (Charge Coupled Device) line sensor that converts an image on the reading surface of the document into image data. Scanner 1 may have the function of scanning a document placed on the document glass. Scanner 1 may also have the function of reading an image from a document transported by an ADF (Auto Document Feeder). Scanner 1 is installed, for example, on top of the main body of an MFP, which is an image forming apparatus 100. Scanner 1 is controlled by the system control unit 5. Scanner 1 outputs the image data of the document to the system control unit 5.

[0020] Printer 2 forms an image on paper, which is used as a recording medium. Printer 2 is, for example, an electrophotographic printer. The image forming method of the image forming apparatus 100 according to this embodiment is not limited to the electrophotographic method. However, in this embodiment, the image forming apparatus 100 will be described as comprising an electrophotographic printer 2. Printer 2 has a color printing function for printing color images on paper and a monochrome printing function for printing monochrome (e.g., black) images on paper. Printer 2 forms color images using multiple toners (e.g., three colors: yellow (Y), cyan (C), and magenta (M)). Printer 2 also forms monochrome images using monochrome (e.g., black (K)) toner.

[0021] In the configuration example shown in Figure 2, the printer 2 has paper feed cassettes 20 (20A, 20B, 20C). The paper feed cassettes 20 are the paper feeding section that supplies paper for printing images. The printer 2 may also have a manual feed tray or the like as a paper feeding section. For example, each of the paper feed cassettes 20A, 20B, and 20C is provided in a detachable manner at the bottom of the MFP body. These paper feed cassettes 20A, 20B, and 20C each store paper of a set type (e.g., size, paper quality).

[0022] Each paper feed cassette 20A, 20B, and 20C has a pickup roller 21A, 21B, and 21C, respectively. The pickup rollers 21A, 21B, and 21C take out one sheet of paper at a time from each paper feed cassette 20A, 20B, and 20C. The pickup rollers 21A, 21B, and 21C supply the taken-out paper to a transport path (transport section 22) which is composed of multiple transport rollers 22A, 22B, 22C, etc.

[0023] The transport unit 22 transports paper within the printer 2. For example, the transport unit 22 transports the paper picked up by the pickup rollers 21A, 21B, and 21C to the registration roller 24. The registration roller 24 transports the paper to the transfer position at the time when it is time to transfer the image from the transfer belt 27 to the paper. The transport unit 22 transports the paper that has passed through the registration roller 24 to the transfer position. The transport unit 22 transports the paper that has passed through the transfer position from the transfer position to the fuser 29. The transport unit 22 transports the paper that has passed through the fuser 29 to either the paper output unit or the automatic double-sided unit (ADU).

[0024] The image forming stations 25 (25Y, 25M, 25C, 25K) form images to be transferred to paper. In the configuration example shown in Figure 2, image forming station 25Y forms an image with yellow toner. Image forming station 25M forms an image with magenta toner. Image forming station 25C forms an image with cyan toner. Image forming station 25K forms an image with black toner.

[0025] Each image forming station 25 (25Y, 25M, 25C, 25K) has a photoreceptor drum 30 (30y, 30m, 30c, 30k), a charger 31 (31y, 31m, 31c, 31k), a developer 32 (32y, 32m, 32c, 32k), a transfer roller 33 (33y, 33m, 33c, 33k), and a cleaner 34 (34y, 34m, 34c, 34k).

[0026] The photoreceptor drum 30 is an image carrier on which an electrostatic latent image is formed. The photoreceptor drum 30 rotates on a rotation axis. The charger 31 charges the surface of the photoreceptor drum 30 to a predetermined potential. The charger 31 has a grid (not shown) for adjusting the charge output to the photoreceptor drum 30. The developer 32 develops the electrostatic latent image formed on the photoreceptor drum 30 with toner. The transfer roller 33 transfers the toner image developed on the photoreceptor drum 30 to the transfer belt 27. The cleaner 34 cleans the surface of the photoreceptor drum 30 after the transfer.

[0027] Furthermore, each image forming station 25 is connected to a toner suction unit 35 and an ozone treatment unit 36. The toner suction unit 35 collects toner scattered between the developer unit 32 and the photoreceptor drum 30 at each image forming station 25. The ozone treatment unit 36 ​​blows outside air into the charger 31 to draw in gas containing ozone, and exhausts the air from which the ozone has been decomposed to the outside of the machine.

[0028] Furthermore, the exposure unit 26 uses laser light to form electrostatic latent images on the photoreceptor drums 30 of each image forming station 25 (25Y, 25M, 25C, 25K). The exposure unit 26 irradiates the photoreceptor drums 30 with laser light controlled according to the image data, via an optical system such as a polygon mirror. The laser light from the exposure unit 26 forms electrostatic latent images on the surface of each photoreceptor drum 30. The exposure unit 26 controls the laser light according to a control signal from the system control unit 5.

[0029] Each image forming station 25 (25Y, 25M, 25C, 25K) develops the electrostatic latent image formed on each photoreceptor drum 30 by each developer 32. Each developer 32 is equipped with a developing container having a developing roller. The developing container holds toner as the developer for each color. The toner is charged by being agitated with the carrier in the developing container. A developing bias is applied to the developing roller 321 (see Figure 4). The developing roller, with the developing bias applied, rotates with toner adsorbed on its surface (circumferential surface), supplying the toner on the circumferential surface to the electrostatic latent image on the photoreceptor drum 30. The electrostatic latent image on the photoreceptor drum 30 is developed as a toner image (visible image) by the supplied toner.

[0030] The developer unit 32 is connected to a toner suction unit 35 for sucking up toner scattered between it and the photoreceptor drum 30. The developer unit 32 collects the toner scattered between it and the photoreceptor drum 30 and sends out the toner suction unit 35. The toner suction unit 35 sucks up the scattered toner between the developer unit 32 and the photoreceptor drum 30 and collects the sucked-up toner with a toner filter 353, which will be described later.

[0031] The transfer belt 27 is an intermediate transfer body. Each image forming station 25 (25Y, 25M, 25C, 25K) applies a primary transfer voltage to the transfer belt 27 using a transfer roller 33, thereby transferring (primary transfer) the toner image formed on the photoreceptor drum 30 onto the transfer belt 27. For example, in image forming station 25K, the transfer roller 33k transfers the toner image developed by the developer 32k with black toner onto the transfer belt 27. When forming a color image, each image forming station 25Y, 25M, 25C, 25K transfers the toner images developed with each color toner onto the transfer belt 27 in layers.

[0032] The transfer unit 28 transfers the toner image on the transfer belt 27 to the paper at the secondary transfer position. The secondary transfer position is the position where the toner image on the transfer belt 27 is transferred to the paper. The secondary transfer position is the position where the support roller 28a and the secondary transfer roller 28b face each other.

[0033] The fuser unit 29 fixes the toner to the paper. The fuser unit 29 applies heat to the paper for fixing. In the example shown in Figure 2, the fuser unit 29 consists of a heat roller 29b with a built-in heating unit 29a and a pressure roller 29c that contacts the fixing belt, which is heated by the heat roller 29b, under pressure. The heating unit 29a can be any heater with controllable temperature. For example, the heating unit 29a may consist of a heater lamp such as a halogen lamp, or it may be an induction heating (IH) type heater. The heating unit 29a may also consist of multiple heaters. The fuser unit 29 transports the fixed paper to either the paper discharge unit or the ADU.

[0034] The control panel 4 is the user interface. The control panel 4 has various buttons and a display unit 4a equipped with a touch panel 4b. The system control unit 5 controls the content displayed on the display unit 4a of the control panel 4. The display unit 4a displays information such as instructions. The control panel 4 also outputs information entered into the touch panel 4b or buttons of the display unit 4a to the system control unit 5. The user can specify the operating mode and input information such as setting information on the control panel 4.

[0035] Next, the configuration of the control system in the image forming apparatus 100 according to this embodiment will be described. Figure 3 is a schematic block diagram showing an example of the configuration of the control system for the system control unit 5 and the printer 2 in the image forming apparatus 100 according to this embodiment. In the configuration example shown in Figure 3, the system control unit 5 includes a system CPU (Central Processing Unit) 51, RAM (Random Access Memory) 52, ROM (Read Only Memory) 53, non-volatile memory (referred to as NVM (Non-volatile Memory) in the figure) 54, HDD (Hard Disk Drive) 55, external interface (referred to as I / F in the figure) 56, input image processing unit 57, page memory 58, and output image processing unit 59.

[0036] The system CPU 51 is a control unit that comprehensively controls each part of the image forming apparatus 100. The system CPU 51 is a processor that performs processing by executing programs. The system CPU 51 is connected to each part of the system control unit 5 via the system bus. The system CPU 51 is also connected to the scanner 1, printer 2, and operation panel 4 via the system bus. The system CPU 51 outputs operation instructions to each part and acquires various information from each part through bidirectional communication with the scanner 1, printer 2, and operation panel 4.

[0037] For example, when the power to the image forming apparatus 100 is turned on, the system CPU 51 operates by executing a program stored in the ROM 53 (or non-volatile memory 54). The system CPU 51 also instructs the printer 2 to print as indicated in the print job when it receives a print job from the user terminal 200. When a copy is instructed on the touch panel 4b of the operation panel 4, the system CPU 51 performs copy control to print the image of the original document scanned by the scanner 1 using the printer 2.

[0038] Furthermore, the CPU, which constitutes the control unit, may be multi-core / multi-threaded, capable of executing multiple processes in parallel. The processor is not limited to a CPU; it may also be an MPU (microprocessing unit). Moreover, the processor may be implemented in various other forms, including integrated circuits such as ASICs (Application Specific Integrated Circuits), GPUs (Graphics Processing Units), FPGAs (field-programmable gate arrays), DSPs (Digital Signal Processors), SoCs (system on a chip), and PLDs (programmable logic devices). The processor may also be a combination of several of these.

[0039] RAM 52 is composed of volatile memory. RAM 52 functions as working memory or buffer memory. ROM 53 is a non-rewritable, non-volatile memory that stores programs and control data. The system CPU 51 performs various processes by executing programs stored in ROM 53 (or non-volatile memory 54, HDD 55) while using RAM 52. For example, the system CPU 51 implements functions to instruct printing and functions to prohibit printing by executing programs.

[0040] The non-volatile memory 54 is a rewritable non-volatile memory. The non-volatile memory 54 stores control programs and control data executed by the system CPU 51. The non-volatile memory 54 also stores various setting information and processing conditions. For example, the non-volatile memory 54 stores setting information for each paper feed cassette (paper feed unit).

[0041] HDD55 is a high-capacity storage device. HDD55 stores image data and various operation history information. HDD55 may also store control programs and control data. HDD55 may also store setting information and processing conditions.

[0042] The external interface 56 is an interface for communicating with external devices. For example, the external interface 56 receives print jobs from an external device, such as a user terminal 200, and sends data to an external device, such as a server device 300. The external interface 56 can be any interface that performs data communication with an external device.

[0043] The input image processing unit 57 processes the image data read by the scanner 1. The input image processing unit 57 has functions such as shading correction, grayscale conversion, line correction, and compression / decompression. The input image processing unit 57 stores the processed image data in the page memory 58.

[0044] The page memory 58 is memory for processing image data. For example, the page memory 58 stores image data processed by the input image processing unit 57 on image data read by the scanner 1. The page memory 58 may also store image data included in a print job acquired via the external interface 56.

[0045] The output image processing unit 59 generates printable image data for the printer 2 to print on paper. The output image processing unit 59 performs image processing to convert the image data stored in the page memory 58 into printable image data. The output image processing unit 59 sends the processed image data to the printer 2.

[0046] Next, we will describe an example of the control system configuration in printer 2. In the configuration example shown in Figure 3, the printer 2 has a control system configuration that includes a printer CPU 61, RAM 62, ROM 63, non-volatile memory (NVM) 64, transport control unit 65, exposure control unit 70, image formation control unit 71, transfer control unit 72, fixing control unit 73, drive control circuit 74, drive control circuit 75, and drive control circuit 76.

[0047] The printer CPU 61 controls the entire printer 2. The printer CPU 61 is a processor that performs processing by executing programs. Note that the processor is not limited to a CPU, but may be implemented in various other forms, including integrated circuits such as MPUs, ASICs, GPUs, FPGAs, DSPs, SoCs, and PLDs. Furthermore, the processor may be a combination of several of these.

[0048] The printer CPU 61 connects to various parts of the printer 2 via a system bus or the like. The printer CPU 61 outputs operation commands to various parts of the printer 2 in response to operation commands from the system CPU 51. The printer CPU 61 also notifies the system CPU 51 of information indicating the processing status in the printer 2.

[0049] RAM62 is composed of volatile memory. RAM62 functions as working memory or buffer memory. ROM63 is a non-rewritable, non-volatile memory that stores programs and control data. The printer CPU61 performs various processes by executing programs stored in ROM63 (or non-volatile memory 64) while using RAM62.

[0050] The non-volatile memory 64 is a rewritable non-volatile memory. For example, the non-volatile memory 64 stores the control program and control data executed by the printer CPU 61, as well as the history data generated by the printer CPU 61 executing the control program. The non-volatile memory 64 may also store setting information and processing conditions.

[0051] The transport control unit 65 controls the transport of paper within the printer 2. The transport control unit 65 controls the driving of the pickup roller 21 and the transport rollers 22A, 22B, 22C of the transport unit 22. The transport control unit 65 controls the driving of the transport rollers 22A, 22B, 22C, which are part of the transport unit 22 within the printer 2, in response to operation instructions from the printer CPU 61. For example, the printer CPU 61 instructs the transport control unit 65 to control paper transport in response to a print start instruction from the system control unit 5.

[0052] The exposure control unit 70 controls the exposure unit 26. The exposure control unit 70 uses the exposure unit 26 to form electrostatic latent images on the photoreceptor drums 30 (30y, 30m, 30c, 30k) of each image forming station 25 (25Y, 25M, 25C, 25K) in response to operation instructions from the printer CPU 61. For example, the exposure control unit 70 controls the laser light that the exposure unit 26 irradiates each photoreceptor drum 30 in accordance with the image data for which the printer CPU 61 instructs the printer to execute printing. For example, the exposure control unit 70 controls the scanning of the laser light emitted by each laser unit based on the BD signal acquired from the exposure unit 26.

[0053] The image forming control unit 71 controls the driving of each image forming station 25 (25Y, 25M, 25C, 25K). For example, the image forming control unit 71 charges the photoreceptor drum 30 to a predetermined potential using a charger 31. The image forming control unit 71 develops the electrostatic latent image formed on the photoreceptor drum 30 after the charging process using a developer 32 toner image of each color. The image forming control unit 71 controls the density of the toner to be developed by controlling the development bias and other parameters for the developer 32. The image forming control unit 71 transfers the toner image developed on the photoreceptor drum 30 to the transfer belt 27 using a transfer roller 33. The image forming control unit 71 also cleans the surface of the photoreceptor drum 30 after the transfer process using a cleaner 34.

[0054] Furthermore, the transfer control unit 72 controls the drive of the transfer unit 28 and the transfer current, etc. The transfer control unit 72 transfers the toner image transferred to the transfer belt 27 to the paper using the transfer unit 28 in accordance with the operation instructions from the printer CPU 61. The fuser control unit 73 controls the drive of the fuser 29. The fuser control unit 73 drives the heat roller 29b and the pressure roller 29c in accordance with the operation instructions from the printer CPU 61. The fuser control unit 73 controls the surface temperature of the heat roller 29b to the fuser temperature by controlling the heating unit 29a.

[0055] The drive control circuit 74 is a circuit that drives the fan motor 354 (see Figure 6) in the toner suction unit 35, which is equipped with a toner filter (filter) 353. The drive control circuit 74 outputs drive power to rotate the fan of the fan motor 354 to achieve a predetermined airflow.

[0056] In the image forming apparatus 100, the program executed by the system CPU 51 or the printer CPU 61 only needs to be stored in a writable storage device. For example, the program may be written to the storage device in response to an operation by an administrator or other person. Furthermore, the transfer of programs, etc., may be done by storing them in a removable computer-readable storage medium or by communication over a network. The computer-readable storage medium can be of any form as long as it can store programs and is readable by the device, such as a CD-ROM or memory card.

[0057] Next, the configuration of the image forming stations 25 (25Y, 25M, 25C, 25K) in the electrophotographic printer 2 of the image forming apparatus 100 will be described in detail. Figure 4 is a cross-sectional view showing an example configuration of the image forming stations 25 (25Y, 25M, 25C, 25K) in the electrophotographic printer 2 of the image forming apparatus 100. As shown in Figure 4, each image forming station 25 has a charger 31, a developer 32, and a cleaner 34 positioned on the surface of a photoreceptor drum 30 that rotates circumferentially in a clockwise direction.

[0058] The charger 31 has a charging needle (charging charger) positioned opposite the surface of the photoreceptor drum 30. The charger 31 generates corona discharge using the charging needle to charge the surface of the photoreceptor drum 30 to a predetermined potential. Ozone is generated inside the charger 31 because the charging needle generates corona discharge. The ozone generated inside the charger 31 is treated by an ozone treatment unit 36 ​​to prevent the photoreceptor drum 30 from degrading due to the ozone.

[0059] The ozone treatment unit 36 ​​decomposes the ozone generated in the charger 31 and releases it outside the housing (machine) of the image forming apparatus 100. The ozone treatment unit 36 ​​sends air taken in from outside the machine into the charger 31, sucks in the ozone-containing air inside the charger 31, decomposes the ozone from the sucked-in air and exhausts it. If foreign matter such as dust accumulates inside the charger 31, discharge will be difficult for the charging needle to occur. For this reason, the ozone treatment unit 36 ​​removes foreign matter such as dust from the air taken in from outside the machine using a filter 361 (see Figure 12), and sends the air that has passed through the filter 361 into the charger 31.

[0060] The surface of the photoreceptor drum 30, which has been charged to a predetermined potential by the charger 31, moves to an exposure position (between the charger 31 and the developer 32) where laser light from the exposure unit 26 is irradiated as the photoreceptor drum 30 rotates. The exposure unit 26 irradiates the surface of the photoreceptor drum 30, which has been charged to a predetermined potential at the exposure position, with laser light controlled according to the image data. An electrostatic latent image corresponding to the image data is formed on the surface of the photoreceptor drum 30 irradiated with laser light from the exposure unit 26.

[0061] Toner, acting as a developer, is supplied from the developer unit 32 to the surface of the photoreceptor drum 30, where an electrostatic latent image has been formed by the exposure unit 26. The electrostatic latent image formed on the surface of the photoreceptor drum 30 is developed as a toner image by the toner supplied from the developer unit 32. In other words, the developer unit 32 creates a visible image (toner image) using toner by supplying a developer (toner) to the electrostatic latent image formed on the surface of the photoreceptor drum 30.

[0062] As shown in Figure 4, the developer unit 32 includes a developing roller 321, a mixer 322, a recovery unit 325, and a recovery roller 326. In the developer unit 32, the mixer 322 agitates the toner and carrier in the developer container. The mixer 322 supplies the toner agitated with the carrier to the surface of the developing roller 321. The developing roller 321 attracts the toner supplied from the mixer 322 to its surface by magnetic force. By rotating with the toner attracted (held) to its surface, the developing roller 321 supplies toner to the surface of the photoreceptor drum 30 that is in close proximity to the developing roller 321 at a predetermined development position. As a result, the electrostatic latent image formed on the photoreceptor drum 30 is developed by the toner supplied from the developing roller 321.

[0063] The toner image, developed as a visible image on the surface of the photoreceptor drum 30, is transferred to the transfer belt 27 by the transfer roller 33 between the developer 32 and the cleaner 34. Furthermore, the toner image transferred to the transfer belt 27 is transferred to the paper. The cleaner 34 is configured to clean the surface of the photoreceptor drum 30 after the toner image has been transferred to the transfer belt 27.

[0064] In the configuration example shown in Figure 4, the developing roller 321 draws air into the developing unit 32 when it rotates in a predetermined direction. As the developing roller 321 rotates, the internal pressure inside the developing unit 32 increases. The developing unit 32 is highly airtight to prevent toner leakage, and gaps that occur at the joints of the parts are filled with sealing material. However, since the developing unit 32 transfers toner to the surface of the photoreceptor drum 30 at the developing position, a gap (air outlet) is formed between the developing unit 32 and the photoreceptor drum 30.

[0065] The air outlet is formed above the area where the surface of the developing roller 321 passes after supplying toner to the photoreceptor drum 30 (above the area where the developing roller 321 and the photoreceptor drum 30 face each other). In the developing unit 32, toner that has been separated from the developing roller 321 and has been lifted into the air by the carrier is attracted towards the air outlet and scattered outside the developing unit 32. The amount of toner scattered outside the developing unit 32 tends to increase as the rotation speed of the developing roller 321 increases.

[0066] The developing unit 32 has a toner scattering collection unit 325 to collect toner scattering from the air outlet. A collection roller 326 is also provided inside the toner scattering collection unit 325. The collection roller 326 attracts toner to its electrically charged surface. The collection unit 325 collects toner by scraping it off the collection roller 326 with a blade. The collection unit 325 is connected to the toner suction unit 35 shown in Figures 5 and 6 via a path shown in Figures 7 and 8, which will be described later. The collection unit 325 sends the toner collected using the collection roller 326, along with air, to the toner suction unit 35 via the path shown in Figures 7 and 8.

[0067] Next, the toner suction unit 35 in the image forming apparatus 100 according to this embodiment will be described. Figure 5 is an external view showing an example of the configuration of the toner suction unit 35 in the image forming apparatus 100 according to the embodiment. Figure 6 is a cross-sectional view showing an example of the internal configuration of the toner suction unit 35. Figures 7 and 8 are diagrams showing an example of the configuration of the connection path between the toner suction unit 35 and the recovery unit 325 of the developer 32 in the image forming station 25.

[0068] As shown in Figure 5, the toner suction unit 35 is formed by a duct 350 having an internal connection part 351 and an external connection part 352. As shown in Figure 6, the toner suction unit 35 includes a toner filter (pressure loss generating component) 353, a weight detection unit 40, and a fan motor 354 inside the duct 350. The toner filter 353 is installed in the middle of the duct 350, which is the air (gas) flow path. The weight detection unit 40 detects the weight of the toner collected by the toner filter 353. The fan motor 354 is installed near the external connection part 352 in the duct 350.

[0069] The fan motor 354 rotates so that the air in the duct 350, which serves as the toner suction unit 35, is discharged from the external connection part 352. The fan motor 354 draws air into the duct 350 from the internal connection part 351 and discharges the air that has passed through the toner filter 353 in the duct 350 from the external connection part 352.

[0070] The toner filter 353 collects toner contained in the air passing through the duct 350 of the toner suction unit 35. As shown in Figure 6, the toner filter 353 is installed in a bag-like shape in relation to the airflow path within the duct 350 to collect the collected toner. The toner filter 353 is installed so that it can be replaced during maintenance.

[0071] The weight detection unit 40 is provided on the toner filter 353 in the configuration shown in Figure 6. The weight detection unit 40 detects the weight of the toner filter 353 when it has collected toner. By subtracting the weight of the toner filter 353 from the weight detected by the weight detection unit 40, the weight of the toner collected by the toner filter 353 is detected. In addition, since the weight detection unit 40 also detects the weight of the toner filter 353 itself, it can detect whether or not the toner filter 353 is installed.

[0072] As shown in Figures 7 and 8, the toner suction unit 35 has an internal connection part 351 that is connected to the recovery part 325 of the developer unit 32 in each image forming station 25. The air in the recovery part 325 of each image forming station 25 is drawn out by the toner suction unit 35. Figures 7 and 8 show the airflow path from the recovery part 325 of the developer unit 32 to the toner suction unit 35 with solid and dotted arrows.

[0073] As shown in Figure 7, the recovery unit 325 of the developing unit 32 transports the air containing toner scattered between the developing roller 321 and the photoreceptor drum 30 to the back side of the image forming apparatus 100 (the connection point of the toner suction unit 35). The air transported to the back side by each recovery unit 325 is collected in a duct connected to the internal connection point 351 of the toner suction unit 35, as shown in Figure 8, and sent into the toner suction unit 35.

[0074] In the toner suction unit 35 shown in Figure 6, the toner filter 353, which acts as a pressure loss generating component, becomes more obstructive to air passage as the amount of collected toner (toner accumulated in the toner filter) increases. When the toner filter 353 becomes less permeable to air due to the collected toner, the toner suction unit 35 has difficulty drawing in toner-containing air from the recovery unit 325. If this condition of difficulty in air flowing from the recovery unit 325 to the toner suction unit 35 continues for a long period of time, toner becomes more likely to scatter inside the machine other than the developer unit 32.

[0075] The image forming apparatus 100 is designed so that the airflow from the recovery unit 325 to the toner suction unit 35 remains normal until the amount of toner collected by the toner filter 353 reaches a predetermined capacity. For this reason, the image forming apparatus 100 is operated under regular maintenance so that the toner filter 353 is replaced before the amount of toner collected by the toner filter 353 reaches a predetermined capacity.

[0076] For example, the image forming apparatus 100 is configured to perform regular maintenance (periodic maintenance) based on the total number of printed pages processed by the printer 2 (total number of prints) or the transport distance (drive counter). The image forming apparatus 100 is operated in such a way that various filters, including the toner filter 353, are replaced during regular maintenance performed by a service technician. The image forming apparatus 100 is designed so that the toner filter 353 maintains normal function until periodic maintenance, assuming that the amount of toner scattered from the developer 32 is within the expected range (normal range). The toner suction unit 35 can recover scattered toner normally by replacing the toner filter 353 at each periodic maintenance, provided that the actual amount of toner scattered is within the expected range.

[0077] However, the actual amount of toner scattered from the developer unit 32 can increase due to various factors. It is difficult to identify in advance the factors that cause toner to scatter beyond the expected range. Therefore, if the amount of toner scattered is significantly higher than expected, it is necessary to prompt maintenance without waiting for scheduled maintenance in order to prevent malfunctions within the machine.

[0078] Figure 9 shows an example of a factor that causes the amount of toner scattered from the developer unit 32 to exceed the expected range. Inside the developing unit 32, the developing roller 321 attracts toner T to its surface (circumferential surface) by magnetic force. The developing roller 321 rotates with the toner T attracted to its circumferential surface, thereby transporting the toner T to the photoreceptor drum 30. As shown in Figure 9, the toner T on the rotating developing roller 321 is held so as to bulge outwards at the magnetic pole positions.

[0079] On the other hand, a developing container formed by combining multiple parts is provided around the developing roller 321 to prevent toner and other materials from being released outside the developing unit 32. The multiple parts forming the developing container of the developing unit 32 are joined together with a sealing material to prevent any gaps. Figure 9 shows an example in which the sealing material S at the joint of the parts inside the developing unit 32 is protruding towards the developing roller 321. In a normal developing unit 32, the sealing material S does not protrude, and the protrusion of the sealing material S as shown in Figure 9 is assumed to be caused by, for example, a defect in the manufacturing process.

[0080] As shown in Figure 9, in the areas where the sealant S protrudes, a portion of the toner T adsorbed on the circumferential surface of the rotating developing roller 321 comes into contact with the sealant S. The toner T in the area that comes into contact with the sealant S is physically peeled off the developing roller 321. As a result, in the developing unit 32 shown in Figure 9, a large amount of toner T, exceeding what was expected due to the protrusion of the sealant S, is peeled off the developing roller 321.

[0081] As described above, within the developing unit 32, as the developing roller 321 rotates, an airflow is generated towards the air outlet (the gap between the developing unit 32 and the photoreceptor drum 30) where the recovery unit 325 is located. As a result, much of the toner T stripped from the developing roller 321 is carried by the airflow within the developing unit 32 and scattered to the recovery unit 325, which is the air outlet. Consequently, as shown in Figure 9, a developing unit 32 with excess sealant S has a significantly larger amount of toner scattered to the recovery unit 325 compared to a developing unit 32 in a normal state.

[0082] If the amount of toner scattered increases due to unexpected factors as shown in Figure 9, the amount of toner collected by the toner filter 353 will exceed the expected range. During normal maintenance (periodic maintenance), the toner filter 353 is replaced assuming that it will recover the toner scattered from the developer unit 32 in a normal state. If the amount of toner scattered exceeds the expected range due to unexpected factors, the amount of toner collected by the toner filter 353 will exceed a predetermined tolerance (toner full) before normal maintenance is performed. When the toner filter 353 becomes toner full, it becomes difficult for air to pass through the toner filter 353. When it becomes difficult for air to pass through the toner filter 353, it becomes difficult for the toner suction unit 35 to suck up toner from the recovery section 325 of each developer unit 32.

[0083] Next, the configuration of the weight detection unit 40, which detects the weight of toner collected by the toner filter 353 in the image forming apparatus 100 according to this embodiment, will be described. Figure 10 shows a weight detection unit 401, which is a first configuration example of a weight detection unit 40 that detects the weight of toner collected by the toner filter 353 in the image forming apparatus 100 according to the embodiment. The weight detection unit 401 in the first configuration example shown in Figure 10 includes a guide 81 and sensors 82 (821, 822, 823, 824). The guide 81 supports the toner filter 353. In the example shown in Figure 10, the guide 81 is provided to support the long side of the toner filter 353, which is set in a box shape in the toner suction unit 35. The guide 81 may also be configured to support the entire outer circumference (all four sides) of the box-shaped toner filter 353 when viewed from above.

[0084] Guide 81 experiences a downward force in response to the gravitational force (downward) acting on the toner filter 353. In other words, guide 81 experiences a downward force in response to the weight of the toner filter 353 itself and the weight of the toner collected by the toner filter 353.

[0085] Sensor 82 outputs a detection signal indicating a downward force applied to the guide 81. Sensor 82 is composed of, for example, a load cell or a load cell including a piezoelectric element. Sensors 82 (821, 822, 823, 824) are provided at the four corners of the guide 81 that supports the toner filter 353. In the example shown in Figure 10, two sensors 821 and 824 are placed at both ends of the guide 81 provided on one long side of the box-shaped toner filter 353, and two sensors 822 and 823 are placed at both ends of the guide 81 provided on the other long side.

[0086] The sum of the values ​​detected by the four sensors 82 represents the weight of the toner filter 353. The weight detected by the four sensors 82 is the sum of the toner filter 353's own weight and the weight of the toner collected by the toner filter 353. The weight of the toner collected by the toner filter 353 is calculated by subtracting the weight of the toner filter 353 from the weight detected by the four sensors 82.

[0087] Figure 11 shows a weight detection unit 402, which is a second configuration example of the weight detection unit 40 that detects the weight of toner collected by the toner filter 353 in the image forming apparatus 100 according to the embodiment. The weight detection unit 402 in the second configuration example shown in Figure 11 includes a guide 83, sensors 84 (841, 842), and a rotating part 85. The guide 83 supports the toner filter 353. In the example shown in Figure 11, the guide 83 is provided to support the long side of the box-shaped toner filter 353. The guide 83 is configured such that one end in the direction of the long side supporting the toner filter 353 is fixed to the rotating part 85, and the other end is movable in the vertical direction. The rotating part 85 is composed of a rotating shaft and a bearing, and is configured so that the guide 83 can move smoothly around the rotating shaft of the rotating part 85.

[0088] In the configuration example shown in Figure 11, sensors 84 (841, 842) are provided at the end of a guide 83 that moves vertically around the rotation axis of the rotating part 85. The guide 83 moves around the rotation axis of the rotating part 85, and a downward force is applied to the movable end on which the sensors 84 are provided in accordance with the force acting on the toner filter 353 in the direction of gravity (downward). In other words, the guide 83 applies a downward force to the end on which the sensors 84 are provided in accordance with the weight of the toner filter 353 and the weight of the toner collected by the toner filter 353.

[0089] Sensor 84 outputs a detection signal indicating a downward force applied at the movable end of guide 83. Sensor 84 is composed of, for example, a load cell or a load cell including a piezoelectric element. Sensors 84 (841, 842) only need to detect the force applied to guide 83 according to the weight of the toner filter. For this reason, there may be one sensor 84 or three or more sensors 84 installed on guide 83.

[0090] As shown in Figure 11, when two sensors 841 and 842 are provided, the sum of the values ​​detected by the two sensors 841 and 842 represents the weight of the toner filter 353. The weight detected by sensor 84 is the sum of the weight of the toner filter 353 itself and the weight of the toner collected by the toner filter 353. The weight of the toner collected by the toner filter 353 is calculated by subtracting the weight of the toner filter 353 from the weight detected by sensor 84.

[0091] Next, a state detection process in which the state of the toner filter 353 is detected by the weight detection unit 401 or weight detection unit 402 in the image forming apparatus 100 according to the embodiment will be described. In the embodiment, the image forming apparatus 100 detects the weight of the toner filter 353 by the weight detection unit 401 or 402. The image forming apparatus 100 determines whether the weight (or change in weight) detected by the weight detection unit 401 or 402 exceeds a predetermined threshold. If the weight detected by the weight detection unit 401 or 402 exceeds the predetermined threshold, and the total number of prints (total number of image formations) is less than a predetermined number, the image forming apparatus 100 stores information indicating that the amount of toner collected by the toner filter 353 is abnormally large as maintenance information to be sent to the server device 300. As a result, the server device 300 can detect that the amount of toner collected by the filter in the image forming apparatus is abnormally large and can provide maintenance guidance accordingly.

[0092] The following describes the state detection process in which the image forming apparatus 100 according to this embodiment detects the state of the toner filter 353 based on the weight detected by the weight detection unit 401 or 402. Figure 12 is a flowchart illustrating the state detection process in which the image forming apparatus 100 according to the embodiment detects the state of the toner filter 353 based on the weight detected by the weight detection unit 401 or 402.

[0093] The system CPU 51 of the image forming apparatus 100 determines whether or not to perform the process of detecting the weight of the toner filter 353 using the weight detection unit 401 or 402 (ACT 10). For example, the system CPU 51 may decide to perform the process of detecting the weight of the toner filter 353 when predetermined conditions are met (for example, when the total number of prints reaches a set number, when maintenance is completed, or during initial setup). The system CPU 51 may also perform weight detection in response to an instruction to perform weight detection or toner filter status detection from the operation panel 4.

[0094] If the system CPU 51 determines that it is time to perform weight detection of the toner filter 353 (ACT10, YES), the drive control circuit 74 stops the fan motor 354 (ACT11). Here, with the fan motor 354 stopped, the weight detection unit 401 or 402 detects the weight of the toner filter 353 (the weight of the toner filter itself and the weight of the toner it has collected). However, the weight detection unit 401 or 402 may also detect the weight of the toner filter 353 while the fan motor 354 is running. In this case, the process of ACT11 is omitted.

[0095] When the system CPU 51 stops the fan motor 354, the weight detection unit 401 or 402 detects the weight of the toner filter 353 (ACT12). The system CPU 51 acquires information indicating the weight of the toner filter 353 detected by the weight detection unit 401 or 402.

[0096] For example, if the weight detection unit 40 is the weight detection unit 401 in the first configuration example shown in Figure 10, the system CPU 51 acquires the values ​​detected by the four sensors 82 (821, 822, 823, 824). The system CPU 51 uses the sum of the values ​​detected by the four sensors 82 as the value indicating the weight of the toner filter 353.

[0097] Furthermore, if the weight detection unit 40 is the weight detection unit 402 in the second configuration example shown in Figure 11, the system CPU 51 acquires the values ​​detected by the two sensors 84 (841, 842) provided at the movable end of the guide 83. The system CPU 51 uses the sum of the values ​​detected by the two sensors 84 as the value indicating the weight of the toner filter 353.

[0098] When the system CPU 51 detects the weight of the toner filter 353 using the weight detection unit 401 or 402, it determines whether or not the toner filter 353 is present (ACT 13). For example, the system CPU 51 determines whether the weight detected by the weight detection unit 401 or 402 is equal to or greater than a predetermined weight that should be detected as the weight of the toner filter 353 itself. If the weight detected by the weight detection unit 401 or 402 is equal to or greater than the predetermined weight, the system CPU 51 determines that the toner filter 353 is set in the predetermined position. If the weight detected by the weight detection unit 401 or 402 is less than the predetermined weight, the system CPU 51 determines that the toner filter 353 is not set in the predetermined position.

[0099] If the system CPU 51 determines that the toner filter 353 is not present (ACT13, NO), it issues a warning that the toner filter 353 is not set in the designated position (ACT14). For example, the system CPU 51 displays an alert on the display unit 4a of the operation panel 4 indicating that the toner filter 353 is not set. The system CPU 51 may also notify the server device 300 that the toner filter 353 is not set. Furthermore, if the system CPU 51 detects that the toner filter 353 is missing, it may stop the printing operation until it detects that the toner filter 353 has been set.

[0100] When the system CPU 51 confirms that the toner filter 353 is installed (ACT13, YES), it determines whether or not to use the weight detected by the weight detection unit 401 or 402 as the initial value (ACT15). If the system CPU R 51 decides to use the detected weight as the initial value (ACT15, YES), it saves it in the NVM 54 as the initial value of the weight of the toner filter 353 detected by the weight detection unit 401 or 402 (ACT16).

[0101] For example, the system CPU 51 stores the weight detected by the weight detection unit 401 or 402 for the first time after installing a new toner filter 353 as an initial value in the NVM 54. Furthermore, when the toner filter 353 is replaced for maintenance or other reasons, the system CPU 51 clears the initial weight of the toner filter 353 stored in the NVM 54. In this case, the system CPU 51 stores the weight detected by the weight detection unit 401 or 402 immediately after the toner filter 353 is replaced as an initial value in the NVM 54.

[0102] Furthermore, if the system CPU 51 does not use the detected weight as the initial value (ACT15, NO), it stores the weight detected by the weight detection unit 401 or 402 (information indicating the weight) in the weight storage area provided in the NVM 54 (ACT17). For example, the system CPU 51 stores information indicating the weight detected by the weight detection unit 401 or 402, along with information indicating the date and time the weight was detected, in the weight storage area.

[0103] The system CPU 51 determines whether the weight change (weight of toner) based on the weight detected by the weight detection unit 401 or 402 and the initial value is greater than or equal to a predetermined threshold (ACT 18). For example, in order to determine whether the amount of toner collected by the toner filter 353 is at the permissible limit (toner full), a predetermined threshold is set according to the weight of the toner amount that the toner filter 353 can tolerate. Alternatively, as part of the determination in ACT 18, the system CPU 51 may determine whether the value obtained by dividing the difference between the initial weight of the toner filter and the weight detected by the weight detection unit 401 or 402 by a predetermined threshold exceeds "1".

[0104] The system CPU 51 determines that the amount of toner collected by the toner filter 353 is not within the acceptable limit if the weight change amount (weight of toner) due to the detected weight is less than a predetermined threshold (ACT18, NO). If the amount of toner collected by the toner filter 353 is not within the acceptable limit, the system CPU 51 terminates the status detection process for the toner filter 353.

[0105] Furthermore, even if the amount of toner collected by the toner filter 353 is not within the acceptable limit, the system CPU 51 may send information indicating the detected weight to the server device 300. For example, the system CPU 51 may send information indicating the weight of toner collected by the toner filter 353, stored in the weight storage area, to the server device 300 as maintenance information.

[0106] The system CPU 51 determines whether the total number of prints (total number of print operations) is greater than or equal to a predetermined number if the weight change amount (weight of toner) detected is greater than or equal to a predetermined threshold (ACT18, YES) (ACT19). The predetermined number relative to the total number of prints is a criterion for determining whether the amount of toner scattering is abnormally high.

[0107] In other words, the image forming apparatus 100 determines that the amount of toner scattered from the developer 32 during printing exceeds the normal range, and that the amount of toner scattered is abnormally high (abnormal toner scattering) when the toner filter 353 reaches its acceptable limit while the total number of prints is clearly low. Conversely, even if the toner filter 353 is judged to be at its acceptable limit, the image forming apparatus 100 will not judge that the amount of toner scattered is abnormal if the total number of prints is equivalent to that of regular maintenance.

[0108] The system CPU 51 of the image forming apparatus 100 determines whether the amount of toner scattered from the developer 32 during printing exceeds the normal range, based on a predetermined number used as a criterion for judgment in relation to the number of prints. The criterion for judging whether the amount of toner scattered is abnormal can be any criterion for judging whether the amount of toner scattered is within the normal range. For example, the predetermined number used as the criterion for judging whether the amount of toner scattered is abnormal does not have to be the total number of prints set as a condition for periodic maintenance. The predetermined number used as the criterion can be set to a value smaller than the total number of prints set as a condition for periodic maintenance.

[0109] If the system CPU 51 determines that the weight change is above a predetermined threshold and the total number of prints is below a predetermined number (ACT19, YES), it stores information indicating that the weight of toner collected by the toner filter 353 is abnormal (abnormal toner collection amount) in memory such as the NVM 54 (ACT20). The information indicating the abnormal toner collection amount may be the weight change (weight of collected toner), or it may be flag information indicating that the toner filter is at its acceptable limit (toner full).

[0110] Furthermore, the system CPU 51 stores information indicating an abnormality in the toner collection amount as part of the information indicating the status of the image forming apparatus 100 (maintenance information) in a predetermined storage area of ​​the NVM 54. The system CPU 51 transmits the maintenance information, including the information indicating an abnormality in the toner collection amount stored in the predetermined storage area of ​​the NVM 54, to the server device 300 at a predetermined transmission cycle (periodically). Alternatively, the system CPU 51 may transmit the maintenance information, including the information indicating an abnormality in the toner collection amount, to the server device 300 whenever it has stored information indicating an abnormality in the toner collection amount in the predetermined storage area, regardless of the predetermined transmission cycle.

[0111] The server device 300 acquires maintenance information from the image forming apparatus 100 via the communication interface 3003. The processor (second processor) 3001 of the server device 300 stores the maintenance information acquired from the image forming apparatus 100 in a database located in memory 3002. The processor 3001 determines the need for maintenance on the image forming apparatus 100 from the maintenance information stored in the database. For example, if the total number of prints reaches the threshold for periodic maintenance, the processor 3001 sends a notification to the service technician terminal 400 prompting periodic maintenance on the image forming apparatus 100.

[0112] Furthermore, when the processor 3001 of the server device 300 receives maintenance information including information indicating an abnormality in the amount of toner collected, it sends a message to the service technician terminal 400 prompting maintenance of the image forming apparatus 100 in accordance with the abnormality in the amount of toner collected. For example, when the processor 3001 receives information indicating an abnormality in the amount of toner collected, it sends a message to the service technician terminal 400 notifying the abnormality in the amount of toner collected. In addition, when the processor 3001 receives information indicating an abnormality in the amount of toner collected, it may also send a message to the service technician terminal 400 prompting the service technician to check for repair or replacement of parts that are causing a large amount of toner scattering (for example, the developing unit).

[0113] (modified version) Next, as a modification of the above-described embodiment, other configuration examples and operation examples of the weight detection unit 40 in the image forming apparatus 100 according to the embodiment will be described. Figure 13 shows a third example of the configuration of a detection unit 403, which is a weight detection unit 40 that detects the weight of toner collected by the toner filter 353 in the image forming apparatus 100 according to the embodiment. The detection unit 401 shown in Figure 13 includes a guide 86, a sensor 87, a rotating part 88, and an elastic member 89.

[0114] The guide 86 supports the toner filter 353. In the example shown in Figure 13, the guide 86 is provided to support the long side of the box-shaped toner filter 353. The guide 86 is configured such that one end in the direction of the long side supporting the toner filter 353 is fixed to the rotating part 88, and the other end is movable in the vertical direction. The rotating part 88 is composed of a rotating shaft and a bearing, and is configured so that the guide 86 can move smoothly around the rotating shaft of the rotating part 88.

[0115] In the configuration example shown in Figure 13, a sensor 87 and an elastic member 89 are provided at the end of a guide 86 that moves vertically around the rotation axis of the rotating part 88. The guide 86 moves around the rotation axis of the rotating part 88, and the movable end on which the sensor 87 is provided moves downward in response to the force acting on the toner filter 353 in the direction of gravity (downward).

[0116] Sensor 87 is composed of, for example, a photosensor. Sensor 87 detects the amount of movement (change) of the movable end of the guide 86 as it moves downward. Sensor 87 only needs to be capable of detecting the amount of change of the movable end of the guide 86 as it moves downward. Sensor 87 also detects whether the movable end of the guide 86 has reached a predetermined measurement target value. In addition, sensor 87 may quantitatively measure the amount of movement of the movable end of the guide 86 as it moves downward.

[0117] The elastic member 89 applies an upward elastic force as the guide 86 moves downward. The elastic member 89 is made of a spring or the like. One end of the elastic member 89 is connected to the movable end of the guide 86, and the other end is connected to a fixed part above the movable end of the guide 86. As a result, the movable end of the guide 86 moves downward to a position where the downward force due to the weight of the toner filter 353 and the upward force due to the elastic member 89 are balanced.

[0118] In the detection unit 403 described above, the sensor 87 is installed to detect when the amount of downward movement of the movable end of the guide 86 reaches a preset measurement target value. For example, the sensor 87 is installed to detect when the movable end of the guide 86 reaches the position where it moves when the toner filter 353 is full of toner (full detection position). This allows the detection unit 403 to detect that the toner filter 353 has reached a toner full state using the sensor 87. The sensor 87 may also include a sensor that detects when the movable end of the guide 86 reaches the position where it moves when a new toner filter 353 is installed (filter presence / absence detection position). This allows the detection unit 403 to detect that the toner filter 353 is installed using the sensor 87.

[0119] Next, a state detection process in which the image forming apparatus 100 according to the embodiment detects the state of the toner filter 353 using the detection unit 403 will be described. In the image forming apparatus 100 according to the embodiment, the detection unit 403 of the third configuration example detects the amount of change in the weight of the toner filter 353 that has collected toner. The image forming apparatus 100 determines whether the amount of change in the weight of the toner filter 353 has reached a predetermined position (full detection position, filter presence / absence detection position). If the detection unit 403 detects that the toner filter 353 is full of toner, and the total number of prints (total number of image formations) is less than a predetermined number, the image forming apparatus 100 stores information indicating that the amount of toner collected by the toner filter 353 is abnormally large as maintenance information to be sent to the server device 300. As a result, the server device 300 can detect that the amount of toner collected by the filter in the image forming apparatus 100 is abnormally large and can provide maintenance guidance accordingly.

[0120] The following describes the state detection process in which the image forming apparatus 100 according to this embodiment detects the state of the toner filter 353 using the detection unit 403. Figure 14 is a flowchart illustrating the state detection process in which the image forming apparatus 100 according to the embodiment detects the state of the toner filter 353 using the detection unit 403.

[0121] The system CPU 51 of the image forming apparatus 100 determines whether or not to execute a process to detect the state of the toner filter 353 using the detection unit 403 (ACT 30). For example, the system CPU 51 may decide to execute a process to detect the state of the toner filter 353 when predetermined conditions are met (for example, when the total number of prints reaches a set number, when maintenance is completed, or during initial setup). Alternatively, the system CPU 51 may also execute the toner filter state detection in response to an instruction to perform toner filter state detection from the operation panel 4.

[0122] If the system CPU 51 determines that it is time to perform a status check on the toner filter 353 (ACT30, YES), the drive control circuit 74 stops the fan motor 354 (ACT31). Here, with the fan motor 354 stopped, the detection unit 403 detects a change in the weight of the toner filter 353 (the weight of the toner filter itself and the weight of the toner it collects). However, the detection unit 403 may also detect the status of the toner filter 353 while the fan motor 354 is running. In this case, the process of ACT31 is omitted.

[0123] When the fan motor 354 is stopped, the system CPU 51 uses the detection unit 403 to detect whether or not the toner filter 353 is installed (ACT 32). The system CPU 51 determines whether or not the toner filter 353 is installed based on whether or not the detection unit 403 has detected the presence of the toner filter 353.

[0124] If the system CPU 51 determines that the toner filter 353 is not present (ACT 32, NO), it issues a warning that the toner filter 353 is not set in the designated position (ACT 33). For example, the system CPU 51 displays an alert on the display unit 4a of the operation panel 4 indicating that the toner filter 353 is not set. The system CPU 51 may also notify the server device 300 that the toner filter 353 is not set. Furthermore, if the system CPU 51 detects that the toner filter 353 is missing, it may stop the printing operation until it detects that the toner filter 353 has been set.

[0125] When the system CPU 51 confirms that the toner filter 353 is installed (ACT 32, YES), it determines whether the toner filter 353 is full of toner (ACT 35). The system CPU 51 determines whether the toner filter 353 is full of toner based on whether the detection unit 403 has detected that the toner filter 353 has reached a toner full state.

[0126] If the system CPU 51 determines that the toner filter 353 is not in a toner-fill state (ACT32, NO), it terminates the toner filter status detection process for the toner filter 353. If the system CPU 51 determines that the toner filter 353 is full of toner (ACT34, YES), it determines whether the total number of prints (total number of print operations) is greater than or equal to a predetermined number (ACT35).

[0127] A predetermined number relative to the total number of prints is a criterion for determining that the amount of toner scattered is abnormally high. In other words, the image forming apparatus 100 determines that the amount of toner scattered is abnormally high (abnormal toner scattering) when the toner filter 353 becomes full of toner while the total number of prints is clearly low (below the predetermined number of prints).

[0128] If the system CPU 51 determines that the toner is full and the total number of prints is less than a predetermined number (ACT35, YES), it stores information indicating that the toner collection amount of the toner filter 353 is abnormal in memory such as the NVM 54 (ACT36). The information indicating the abnormal toner collection amount may be flag information indicating that the toner filter 353 is at its acceptable limit (toner full).

[0129] Furthermore, the system CPU 51 stores information indicating an abnormality in the toner collection amount as part of the information indicating the status of the image forming apparatus 100 (maintenance information) in a predetermined storage area of ​​the NVM 54. The system CPU 51 transmits the maintenance information, including the information indicating an abnormality in the toner collection amount stored in the predetermined storage area of ​​the NVM 54, to the server device 300 at a predetermined transmission cycle (periodically). Alternatively, the system CPU 51 may transmit the maintenance information, including the information indicating an abnormality in the toner collection amount, to the server device 300 whenever it has stored information indicating an abnormality in the toner collection amount in the predetermined storage area, regardless of the predetermined transmission cycle.

[0130] The server device 300 acquires maintenance information from the image forming apparatus 100 via the communication interface 3003. The processor (second processor) 3001 of the server device 300 stores the maintenance information acquired from the image forming apparatus 100 in a database located in memory 3002. The processor 3001 determines the need for maintenance on the image forming apparatus 100 from the maintenance information stored in the database. For example, if the total number of prints reaches the threshold for periodic maintenance, the processor 3001 sends a notification to the service technician terminal 400 prompting periodic maintenance on the image forming apparatus 100.

[0131] Furthermore, when the processor 3001 of the server device 300 receives maintenance information including information indicating an abnormality in the amount of toner collected, it sends a message to the service technician terminal 400 prompting maintenance of the image forming apparatus 100 in accordance with the abnormality in the amount of toner collected. For example, when the processor 3001 receives information indicating an abnormality in the amount of toner collected, it sends a message to the service technician terminal 400 notifying the abnormality in the amount of toner collected. In addition, when the processor 3001 receives information indicating an abnormality in the amount of toner collected, it may also send a message to the service technician terminal 400 prompting the service technician to check for repair or replacement of parts that are causing a large amount of toner scattering (for example, the developing unit).

[0132] As described above, the image forming apparatus according to the embodiment can detect when the amount of toner collected by the toner filter has reached an acceptable limit by detecting the weight of the toner filter. Furthermore, when the amount of toner collected reaches an acceptable limit, the image forming apparatus can determine whether the amount of toner collected by the toner filter is abnormally high based on the total number of image forming operations. If the image forming apparatus detects that the amount of toner collected is abnormally high, it can provide maintenance information, including the abnormality in the amount of toner collected, to the server device.

[0133] This allows the server device to notify service personnel if the amount of toner collected in the image forming apparatus is abnormally high. Furthermore, the server device can estimate that there is an abnormal amount of toner scattering from the developer unit and prompt the replacement of the developer unit, which is suspected to be malfunctioning. As a result, the image forming apparatus can prevent malfunctions caused by toner scattering inside the machine, reducing the time and cost associated with maintenance such as cleaning and parts replacement.

[0134] While several embodiments of the present invention have been described, these embodiments are presented as examples only and are not intended to limit the scope of the invention. These novel embodiments can be carried out in a variety of other forms, and various omissions, substitutions, and modifications can be made without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, as well as in the claims of the invention and its equivalents.

[0135] As described above, the following image forming apparatus, storage medium, and image forming system can be implemented according to the detailed embodiments. [1] An image forming station that uses toner to perform image formation, A filter for collecting toner scattered from the image forming station, A sensor that detects the weight of the filter, including the toner collected by the filter, A processor that detects information indicating an abnormality in the amount of toner collected in the filter when the weight detected by the sensor exceeds a predetermined threshold before the predetermined maintenance period is reached, An image forming apparatus having [2] Furthermore, it has a memory that stores the value detected by the sensor as the initial value of the filter's weight. The processor detects an abnormality in the amount of toner collected in the filter when the weight change amount, calculated by the weight detected by the sensor and the initial value, exceeds a predetermined threshold. [1] The image forming apparatus described above. [3] Furthermore, the duct in which the filter is installed, The duct is equipped with a fan motor that sucks in air containing toner scattered from the image forming station, The processor detects the weight of the filter using the sensor when the fan motor is stopped. [1] The image forming apparatus described above. [4] The processor detects that the filter is not set in the predetermined position based on the weight detected by the sensor. [1] The image forming apparatus described above. [5] It has an external interface for communicating with the server device, The processor transmits information indicating an abnormality in the amount of toner collected in the filter to the server device via the external interface. [1] The image forming apparatus described above. [6] A processor in an image forming apparatus having an image forming station that performs image formation using toner and a filter that collects toner scattered from the image forming station, A sensor detects a value indicating the weight of the filter, including the toner collected by the filter. The system determines whether the weight detected by the aforementioned sensor exceeds a predetermined threshold. If the weight detected by the sensor exceeds a predetermined threshold, it is determined whether the number of image formation cycles performed by the image forming station has reached a predetermined number. If the weight detected by the sensor exceeds a predetermined threshold, and before the number of image formation cycles by the image forming station reaches a predetermined number, information indicating an abnormality in the amount of toner collected in the filter is recorded in the memory. A non-temporary storage medium that stores a program to execute a task. [7] The sensor is a device that detects the force generated by the weight of the filter. [1] The image forming apparatus described above. [8] The aforementioned sensor is a load cell. [7] The image forming apparatus described above. [9] The load cell includes a piezoelectric element, [7] The image forming apparatus described above.

[10] The filter has a guide that supports the filter and is movable by the force generated by the weight of the filter, The sensor is installed in a position to detect the force applied to the guide. [1] The image forming apparatus described above.

[11] The aforementioned sensors are multiple in number and are installed at multiple locations on the guide. The aforementioned processor detects weight based on the sum of values ​​detected by multiple sensors.

[10] The image forming apparatus described above.

[12] The guide has one end fixed to the rotating part, and the other end is movable around the rotation axis of the rotating part. The sensor is installed on the movable end of the guide.

[10] The image forming apparatus described above.

[13] The sensors are multiple in number and are installed at multiple locations on the movable end of the guide.

[12] The image forming apparatus described above.

[14] Furthermore, it has a guide that supports the filter and moves downward due to the force generated by the weight of the filter, The sensor is a photosensor that detects the amount of downward movement of the guide. [1] The image forming apparatus described above.

[15] Furthermore, it has an elastic member that applies an upward force when the guide moves downward, The image forming apparatus described in

[14] .

[16] The guide has one end fixed to the rotating part, and the other end is movable around the rotation axis of the rotating part. The photosensor detects the amount of downward movement of the movable end of the guide.

[13] The image forming apparatus described above.

[17] In an image forming system including an image forming apparatus and a server apparatus, The image forming apparatus is An external interface that communicates with the aforementioned server device, An image forming station that uses toner to perform image formation, A filter for collecting toner scattered from the image forming station, A sensor that detects the weight of the filter, including the toner collected by the filter, The system includes a first processor that transmits information to the server device indicating an abnormality in the amount of toner collected in the filter when the weight detected by the sensor exceeds a predetermined threshold before the number of image formation cycles reaches a predetermined number, The server device is A communication interface for communicating with the image forming apparatus and the service terminal, The system includes a second processor that, when it obtains information from the image forming apparatus via the communication interface indicating an abnormality in the amount of toner collected in the filter, transmits a message to the service technician terminal prompting maintenance of the image forming apparatus. Image forming system. [Explanation of Symbols]

[0136] 2…Printer, 4…Operation panel, 5…System control unit, 25(25Y, 25M, 25C, 25K)…Image forming station, 26…Explorer, 27…Transfer belt, 28…Transfer unit, 30(30y, 30m, 30c, 30k)…Photoconductor drum, 31(31y, 31m, 31c, 31k)…Charger, 32(32y, 32m, 32c, 32k)…Developer, 325…Recovery unit, 33(33y, 33m, 33c, 33k)…Transfer roller, 34(34y, 34m, 34c, 34k)…Cleaner, 35…Toner suction unit, 350…Duct (transport path), 353…Filter (toner filter), 354…Fan motor, 4 0...Weight detection unit, 401...Weight detection unit, 402...Weight detection unit, 403...Detection unit, 51...System CPU (processor, first processor), 52, 62...RAM, 53, 63...ROM, 54, 64...Non-volatile memory (NVM), 55...HDD, 56...External interface (I / F), 61...Printer CPU, 65...Transport control unit, 70...Exposure control unit, 71...Image formation control unit, 72...Transfer control unit, 100...Image forming apparatus, 200...User terminal, 300...Server device, 3001...Processor (second processor), 3002...Memory, 3003...Communication interface (I / F), 400...Service technician terminal.

Claims

1. An image forming station that uses toner to perform image formation, A filter for collecting toner scattered from the image forming station, A sensor that detects the weight of the filter, including the toner collected by the filter, A processor that detects information indicating an abnormality in the amount of toner collected in the filter when the weight detected by the sensor exceeds a predetermined threshold before the predetermined maintenance period is reached, An image forming apparatus having

2. Furthermore, it has a memory that stores the value detected by the sensor as the initial value of the filter's weight. The processor detects an abnormality in the amount of toner collected in the filter when the weight change amount, calculated by the weight detected by the sensor and the initial value, exceeds a predetermined threshold. The image forming apparatus according to claim 1.

3. Furthermore, the duct in which the filter is installed, The duct is equipped with a fan motor that sucks in air containing toner scattered from the image forming station, The processor detects the weight of the filter using the sensor when the fan motor is stopped. The image forming apparatus according to claim 1.

4. The processor detects that the filter is not set in the predetermined position based on the weight detected by the sensor. The image forming apparatus according to claim 1.

5. It has an external interface for communicating with the server device, The processor transmits information indicating an abnormality in the amount of toner collected in the filter to the server device via the external interface. The image forming apparatus according to claim 1.

6. A processor in an image forming apparatus having an image forming station that performs image formation using toner and a filter that collects toner scattered from the image forming station, A sensor detects a value indicating the weight of the filter, including the toner collected by the filter. The system determines whether the weight detected by the aforementioned sensor exceeds a predetermined threshold. If the weight detected by the sensor exceeds a predetermined threshold, it is determined whether the number of image formation cycles performed by the image forming station has reached a predetermined number. If the weight detected by the sensor exceeds a predetermined threshold, and before the number of image formation cycles by the image forming station reaches a predetermined number, information indicating an abnormality in the amount of toner collected in the filter is recorded in the memory. A program that performs an action.

Images