Image forming apparatus, method, and program

Abstract

To more reliably suppress powder from overflowing from a powder storage container in an image forming device.SOLUTION: An image forming device that forms an image on a recording medium comprises a powder storage container, a drive source 31, first powder amount detection means 112, and a powder amount sensor 21 serving as second powder amount detection means. The powder storage container is replaceably provided to the image forming device, and stores waste toner as powder remaining from image formation. The drive source 31 drives a movement member that moves waste toner in the powder storage container. The first powder amount detection means 112 detects the amount of waste toner in the powder storage container on the basis of a value relating to the load torque of the drive source 31. The powder amount sensor 21 differs in type from the first powder amount detection means and detects the amount of waste toner in the powder storage container.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] The present invention relates to an image forming apparatus, method and program.

Background Art

[0002] An image forming apparatus is provided with a collected toner box (powder container) for collecting toner (powder) remaining after image formation (see, for example, paragraphs

[0057] to

[0058] of Patent Document 1). This image forming apparatus has a sensor that detects when the inside of the collected toner box is nearly full. As developer accumulates in the collected toner box, the powder surface rises, and when the sensor detects the powder surface, it is determined that the collected toner box is full.

Prior Art Literature

Patent Literature

[0003]

Patent Document 1

Summary of the Invention

Problem to be Solved by the Invention

[0004] However, in the image forming apparatus described in Patent Document 1, if the sensor fails or experiences detection failure, waste toner (powder) overflows from the collected toner box (powder container), and the waste toner path connected to the collected toner box becomes clogged. There is usually no means for detecting this clogging of the waste toner path, and the clogging is only discovered after it has spread over a wide area. The clogging of the waste toner path that has spread over a wide area, combined with the configuration in which the waste toner path is installed at a deep position inside the image forming apparatus, makes repair difficult.

[0005] An object of the present invention is to more reliably suppress overflow of powder from a powder container in an image forming apparatus.

Means for Solving the Problem

[0006] The above objectives of the present invention are achieved by the following means.

[0007] (1) An image forming apparatus for forming an image on a recording medium, comprising: a powder container provided interchangeably with the image forming apparatus for containing powder remaining after image forming; a drive source for driving a moving member for moving powder within the powder container; a first powder quantity detection means for detecting the amount of powder in the powder container based on a value relating to the load torque of the drive source; and a second powder quantity detection means of a different type from the first powder quantity detection means for detecting the amount of powder in the powder container. The drive source is connected to the movable member provided in the powder container via a drive coupling, the drive coupling having a first coupling on the drive source side and a second coupling on the powder container side, the second coupling having less coupling strength than the first coupling. Image forming apparatus.

[0008] (2) The image forming apparatus according to (1), wherein the second powder quantity detection means is an optical sensor.

[0009] (3) The image forming apparatus according to (1), wherein the value relating to the load torque of the drive source is determined from the value of the electrical input supplied to the drive source.

[0010] (4) The image forming apparatus according to (3), wherein the value of the electrical input is a current value.

[0011] (5) The image forming apparatus according to (1), which issues an instruction to replace the powder container based on the detected amount of powder in the powder container.

[0012] (6) The image forming apparatus according to (5), wherein the replacement instruction is issued based on the detection result by the first powder quantity detection means or the detection result by the second powder quantity detection means.

[0013] (7) The image forming apparatus according to (6), wherein the timing of issuing the replacement instruction differs depending on whether the replacement instruction is issued based on the detection result of the first powder quantity detection means or based on the detection result of the second powder quantity detection means.

[0014] (8) The image forming apparatus according to (7), wherein the replacement instruction issued based on the detection result of the second powder quantity detection means is issued before the replacement instruction issued based on the detection result of the first powder quantity detection means.

[0015] (9) The image forming apparatus according to (6), wherein when the replacement instruction is issued based on the detection result by the first powder quantity detection means, it is set to a state in which it does not accept new print jobs.

[0016] (10) The image forming apparatus according to (9), wherein the state of not accepting new print jobs is released when the powder container is replaced.

[0017] (11) The image forming apparatus according to (1), wherein the value relating to the load torque of the drive source is determined by the difference between the value relating to the load torque of the drive source measured in a predetermined interval and the current value relating to the load torque of the drive source.

[0018] (12) The image forming apparatus according to (11), wherein the value relating to the load torque of the drive source measured in the predetermined section is updated at regular intervals.

[0019] (13) The image forming apparatus according to (12), wherein the fixed interval is set by the number of printed sheets or the operating time of the image forming apparatus.

[0020] (14) The image forming apparatus according to (11), wherein the value relating to the load torque of the drive source measured in the predetermined section is updated when the powder container is replaced.

[0021] (15) The image forming apparatus according to (11), which issues an instruction to replace the powder container when the current load torque value of the drive source becomes less than or equal to a certain value than the value of the load torque of the drive source measured in the predetermined section.

[0022] (16) The image forming apparatus according to (15), wherein when an instruction to replace the powder container is issued, the ongoing print job is stopped and the apparatus is set to a state of not accepting new print jobs.

[0023] (17) The image forming apparatus according to (16), wherein the stopping of the ongoing print job and the state of not accepting new print jobs are canceled when the powder container is replaced.

[0024] (18) The image forming apparatus according to (1), wherein the moving member is rotatable, and the value related to the load torque of the drive source is determined based on results of a plurality of measurements performed while the moving member rotates once.

[0025] (19) The image forming apparatus according to (1), wherein the drive source is coupled to the moving member provided in the powder container via a drive coupling portion, and the drive coupling portion is disconnected when the load torque of the drive source reaches or exceeds a predetermined value.

[0027] (20) A method used in the image forming apparatus, the image forming apparatus comprising: a powder container replaceably provided in the image forming apparatus, configured to store powder remaining after image formation; and a drive source configured to drive a moving member configured to move powder in the powder container, the method comprising: a first powder amount detection step of detecting the amount of powder in the powder container based on a value related to load torque of the drive source; and a second powder amount detection step of a different type from the first powder amount detection step, the second powder amount detection step detecting the amount of powder in the powder container Furthermore, the drive source is connected to the movable member provided in the powder container via a drive coupling, and the drive coupling has a first coupling on the drive source side and a second coupling on the powder container side, and the second coupling has a lower coupling strength than the first coupling. , which is the method.

[0028] (21)A program for controlling an image forming apparatus comprising a powder container for containing powder remaining after image forming, which is interchangeably provided to the image forming apparatus, and a drive source for driving a moving member for moving powder within the powder container, wherein the program causes the computer to execute a first powder quantity detection procedure for detecting the amount of powder in the powder container based on a value relating to the load torque of the drive source, and a second powder quantity detection procedure of a different type from the first powder quantity detection procedure for detecting the amount of powder in the powder container. The drive source is connected to the movable member provided in the powder container via a drive coupling, and the drive coupling has a first coupling on the drive source side and a second coupling on the powder container side, and the second coupling has less coupling strength than the first coupling. program. [Effects of the Invention]

[0029] According to the present invention, it is possible to more reliably suppress the overflow of powder from the powder container in an image forming apparatus. [Brief explanation of the drawing]

[0030] [Figure 1] This is a schematic diagram showing the configuration of an image forming apparatus according to an embodiment of the present invention. [Figure 2] This is a schematic perspective view showing how a powder container is attached to and detached from an image forming apparatus. [Figure 3] This is a schematic side cross-sectional view showing the structure of a powder container. [Figure 4] This is a schematic cross-sectional view along the line IV-IV in Figure 3. [Figure 5] Figure 3 is a schematic perspective view showing a drive mechanism including a drive source that drives the moving member shown. [Figure 6] Figure 5 is a schematic perspective view showing the main parts of the drive coupling section of the drive mechanism. [Figure 7] This is a side view illustrating the state of the drive coupling during normal use. [Figure 8] This is a side view illustrating the state of the drive coupling section 32 under overload conditions. [Figure 9] This block diagram shows a control configuration for monitoring the amount of waste toner in a powder container. [Figure 10] This flowchart shows the details of the monitoring process performed by the first powder quantity detection means. [Figure 11] This flowchart shows the monitoring process using a powder quantity sensor as the second means of detecting the amount of powder. [Modes for carrying out the invention]

[0031] In each figure, common or similar components are denoted by the same reference numeral, and redundant explanations for them are omitted as appropriate. Note that the size and shape of components may be simplified or exaggerated for illustrative purposes.

[0032] Figure 1 is a schematic diagram showing the configuration of an image forming apparatus according to an embodiment. As shown in Figure 1, the image forming apparatus 100 comprises a control unit 110, an image forming unit 120, a fixing unit 130, an operation display unit 140, an image reading unit 170, a paper feeding and transport unit 180, and a powder container 10.

[0033] The control unit 110, like a general computer, reads and executes various programs as appropriate to realize various functions of the image forming apparatus 100.

[0034] The image forming unit 120 includes an image forming unit 121Y that forms a yellow (Y) colored image, an image forming unit 121M that forms a magenta (M) colored image, an image forming unit 121C that forms a cyan (C) colored image, and an image forming unit 121K that forms a black (K) colored image. The image forming unit 121Y includes a photosensitive drum 125Y, a charging unit 126Y arranged around the photosensitive drum 125Y, a developing unit 127Y, a drum cleaner 128Y, and an optical writing unit 129Y. The image forming units 121M, 121C, and 121K have the same configuration as the image forming unit 121Y except for the difference in color, so their descriptions are omitted. In the following description, the symbols Y, M, C, and K will not be used unless it is necessary to distinguish them.

[0035] The fixing unit 130 includes a heating roller equipped with a heater, a fixing roller, a tensioning roller, and a fixing belt wound around these rollers, and fixes the image transferred onto the paper S.

[0036] The operation display unit 140 is, for example, a touch sensor superimposed on the display surface of a liquid crystal display, and displays operation screens and various images, and receives input from the user for various operations. The image reading unit 170 reads the image of the original document. The read image is then formed into an image by the image forming unit 120 according to instructions from the operation display unit 140.

[0037] The paper feed transport unit 180 is equipped with multiple transport roller pairs driven by transport motors (not shown). A large number of sheets of paper S are stored inside the paper feed tray 181. The sheets of paper S stored in the paper feed tray 181 are fed out one by one from the top and transported toward the image forming unit 120. At this time, the sheets of paper S fed into the registration roller pair 185 are brought into contact with the registration roller pair 185, correcting their tilt and adjusting the transport timing.

[0038] An output tray 188 for receiving the printed paper S is provided on the outside of the housing 101 of the image forming apparatus 100. The powder container 10 contains waste toner 13 (powder; see Figure 3, the same applies hereafter), which is the toner remaining after image formation. Details of the powder container 10 will be described later.

[0039] The operation of the image forming apparatus 100 is a general electrophotographic image forming operation, so a detailed explanation will be omitted, but the general outline is as follows. The image forming apparatus 100 writes an image information signal to the surface of the photoreceptor drum 125 using the optical writing unit 129, forming a latent image on the surface of the photoreceptor drum 125 based on the image information signal. The latent image is developed by the toner developer in the developing unit 127, forming a visible image, which is a toner image, on the surface of the photoreceptor drum 125.

[0040] The toner images of each color are sequentially stacked on the intermediate transfer belt 122 and transferred onto the paper S by the secondary transfer roller 123. The paper S with the transferred image is transported to the fuser unit 130, where the toner image is fixed to the paper S and output to the output tray 188. Toner remaining on the surface of the photoconductor drum 125 is scraped off by the drum cleaner 128 and collected as waste toner 13 in the powder container 10 via the waste toner path 90. Similarly, toner remaining on the surface of the intermediate transfer belt 122 is scraped off by the intermediate transfer belt cleaner 124 and collected as waste toner 13 in the powder container 10 via the waste toner path 90.

[0041] Figure 2 is a schematic perspective view showing the attachment and detachment of the powder container 10 to the image forming apparatus 100. Figure 3 is a schematic side cross-sectional view showing the configuration of the powder container 10. Figure 4 is a schematic cross-sectional view along the line IV-IV in Figure 3.

[0042] As shown in Figure 2, the powder container 10 is interchangeably provided on the image forming apparatus 100. The powder container 10 can be attached to and detached from the image forming apparatus 100 with the door 102, which is openable and closable on the housing 101, open.

[0043] As shown in Figures 3 and 4, a powder collection port 11 is provided near one end of the powder container 10. The powder collection port 11 is connected to the waste toner path 90 (see Figure 1). As shown in Figure 3, a moving member 12 is provided inside the powder container 10 to move the waste toner 13 from the powder collection port 11 in a substantially horizontal direction. The moving member 12 extends from one end on the powder collection port 11 side to near the other end on the far side inside the powder container 10. The moving member 12 is coil-shaped or screw-shaped and rotates around its longitudinal center by a drive source 31 (see Figure 5).

[0044] The drive source 31 is an electric motor, such as a DC brushless motor. The moving member 12 rotates to move the waste toner 13 inside the powder container 10 in a direction away from the powder collection port 11. In other words, in this embodiment, the powder collection port 11 is located at the end of the powder container 10 in the opposite direction to the direction in which the waste toner 13 is moved by the moving member 12. Also, the powder collection port 11 is located on top of the moving member 12. Therefore, a large amount of waste toner 13 that enters from the powder collection port 11 can be moved inside the powder container 10 in a direction away from the powder collection port 11. As a result, waste toner 13 accumulates from end to end inside the powder container 10, so the capacity of the powder container 10 can be effectively utilized.

[0045] As shown in Figure 4, a sensor mounting portion 15 is provided on one side of the powder container 10. The sensor mounting portion 15 is a part that protrudes from one side of the powder container 10. The side on which the sensor mounting portion 15 is installed is one of the sides in the direction along the direction of movement of the waste toner 13 by the moving member 12. When viewed from the inside of the powder container 10, the sensor mounting portion 15 is a recess. The sensor mounting portion 15 is provided with an opening 15a inside the recess for taking in the waste toner 13.

[0046] A powder quantity sensor 21, which serves as a second powder quantity detection means, is attached to the sensor mounting section 15. The powder quantity sensor 21 detects the amount of waste toner 13 in the powder container 10 by directly sensing the waste toner 13 in the powder container 10. The powder quantity sensor 21 is fixed to the image forming apparatus 100. Therefore, the sensor mounting section 15 is positioned to align with the powder quantity sensor 21 when the powder container 10 is set in the image forming apparatus 100.

[0047] In this embodiment, the powder quantity sensor 21 is an optical sensor. The output state of the signal of the optical sensor changes depending on whether or not light from the light irradiation unit reaches the light receiving unit. The control unit 110 can determine from the signal from the powder quantity sensor 21 whether or not the waste toner 13 in the powder container 10 has reached, for example, the full capacity position 13a.

[0048] The sensor mounting section 15 is positioned between the light-emitting section and the light-receiving section of the powder quantity sensor 21 when the powder container 10 is attached to the image forming apparatus 100. The sensor mounting section 15 has a light-transmitting member. Light from the light-emitting section of the powder quantity sensor 21 passes through the light-transmitting member of the sensor mounting section 15, through the inside of the powder container 10, and then again through the light-transmitting member to reach the light-receiving section of the powder quantity sensor 21. Therefore, the light from the light-emitting section of the powder quantity sensor 21 is blocked when there is waste toner 13 inside the sensor mounting section 15.

[0049] Figure 5 is a schematic perspective view showing a drive mechanism 30 including a drive source 31 that drives the movable member 12 shown in Figure 3. Figure 6 is a schematic perspective view showing the main part of the drive coupling portion 32 of the drive mechanism 30 shown in Figure 5. Figure 7 is a side view illustrating the state of the drive coupling portion 32 during normal use. Figure 8 is a side view illustrating the state of the drive coupling portion 32 during overload.

[0050] As shown in Figure 5, the drive mechanism 30, which includes a drive source 31 that drives the movable member 12, is equipped with a drive coupling portion 32. In other words, the drive source 31 is connected to the movable member 12, which is provided inside the powder container 10, via the drive coupling portion 32. The drive coupling portion 32 has a first coupling portion 33 on the drive source 31 side and a second coupling portion 34 on the powder container 10 side.

[0051] The first connecting section 33 includes a first coupling 38 through which the rotation of the rotating shaft of the drive source 31 is transmitted via gears 35-37. A gear 39 that meshes with gear 37 is formed on the outer circumferential surface of the first coupling 38. The second connecting section 34 includes a second coupling 40 that can be connected to the first coupling 38.

[0052] As shown in Figure 6, the first coupling 38 has a first engagement portion 41 having a first tapered surface 41a. The first coupling 38 is biased toward the second coupling 40 by a biasing member 45 such as a spring member. The end of the biasing member 45 opposite to the first coupling 38 is fixed to the housing 101. The second coupling 40 has a second engagement portion 42 having a second tapered surface 42a that can transmit rotational force when in contact with the first tapered surface 41a. The second engagement portion 42 is rotatably supported by a housing 43 (see Figure 7) fixed to the powder container 10. A movable member 12 is fixed to the end 44 of the second engagement portion 42.

[0053] As shown in Figure 7, during normal use, the biasing member 45 presses the first coupling 38 toward the second coupling 40, thereby maintaining the connection between the first coupling 38 and the second coupling 40. On the other hand, during overload when the load torque of the drive source 31 exceeds a predetermined value, the reaction force from the second tapered surface 42a to the first tapered surface 41a increases, as shown in Figure 8, causing the first coupling 38 to retract in the direction of arrow A in Figure 8. As a result, the connection between the first coupling 38 and the second coupling 40 is broken.

[0054] Figure 9 is a block diagram showing a control configuration for monitoring the amount of waste toner 13 in the powder container 10. As shown in Figure 9, the control unit 110 includes a CPU and a memory unit, and controls each part of the image forming apparatus 100. The control unit 110 controls the drive source 31 via the drive source control unit 111. Specifically, the control unit 110 outputs a command value for the target rotational speed of the drive source 31 to the drive source control unit 111, and the drive source control unit 111 supplies a current to the drive source 31 according to the command value for the target rotational speed. The control unit 110 is equipped with a first powder quantity detection means 112. The function of the first powder quantity detection means 112 is realized by the CPU executing a predetermined program stored in the memory unit. The first powder quantity detection means 112 determines a value related to the load torque of the drive source 31 from the value of the current supplied to the drive source 31, and detects the amount of waste toner 13 in the powder container 10 based on the value related to the load torque of the drive source 31. The signal regarding the amount of waste toner 13 in the powder container 10, detected by the powder quantity sensor 21, which serves as a second powder quantity detection means, is input to the control unit 110. The control unit 110 performs processes such as issuing a replacement instruction by displaying a message prompting the replacement of the powder container 10 on the operation display unit 140, based on the detected amount of waste toner 13 in the powder container 10.

[0055] Next, referring to Figures 10 and 11, the process for monitoring the amount of waste toner 13 in the powder container 10 will be described. Figure 10 is a flowchart showing the contents of the monitoring process by the first powder quantity detection means 112.

[0056] As shown in Figure 10, the first powder quantity detection means 112 of the control unit 110 first determines whether the current update timer (not shown) has reached T1(s) or more (step S11). If the current update timer has reached T1(s) or more (Yes in step S11), the process proceeds to step S12. If the current update timer has not reached T1(s) or more (No in step S11), the determination in step S11 is repeated. The current update timer is a timer built into the control unit 110 and is cleared when the process proceeds to step S12.

[0057] In step S12, the first powder quantity detection means 112 records the value of the current supplied to the drive source 31 in the storage unit. That is, the current value is recorded at regular intervals T1(s). In step S13, the first powder quantity detection means 112 updates the current value. To suppress variations in rotational drive, the current value is calculated by averaging the current values ​​over the most recent time period T2[s], not just the last recorded current value.

[0058] In step S14, the first powder quantity detection means 112 calculates a value related to the load torque of the drive source 31. The value related to the load torque of the drive source 31 is obtained by subtracting the base current value, which is the value related to the load torque of the drive source 31 measured over a defined period, from the current current value, which is the value related to the load torque of the drive source 31 at the moment.

[0059] In this embodiment, the base current value is a reference current value that is updated under certain conditions. Specifically, the base current value is configured to be updated at regular intervals set by, for example, the number of printed pages or the operating time of the image forming apparatus 100. Furthermore, the base current value is configured to be updated when the powder container 10 is replaced.

[0060] In step S15, the first powder quantity detection means 112 determines whether the value of the load torque of the drive source 31 obtained in step S14 is an abnormal value. Specifically, if the value of the load torque of the drive source 31 exceeds a predetermined upper limit, or if it falls below a certain value, it is determined to be an abnormal value. If the value of the load torque of the drive source 31 is an abnormal value (Yes in step S15), the process proceeds to step S16; otherwise, it is not an abnormal value (No in step S15), the process returns to step S11.

[0061] In step S16, the first powder quantity detection means 112 performs load torque abnormality processing. Specifically, if the value related to the load torque of the drive source 31 exceeds a predetermined upper limit, the first powder quantity detection means 112 issues an instruction to replace the powder container 10. In addition, the first powder quantity detection means 112 sets the system to a state where it will not accept new print jobs. On the other hand, if the value related to the load torque of the drive source 31 falls below a certain value, the first powder quantity detection means 112 issues an instruction to replace the powder container 10. In addition, the first powder quantity detection means 112 stops the currently running print job and sets the system to a state where it will not accept new print jobs.

[0062] Figure 11 is a flowchart showing the monitoring process performed by the powder quantity sensor 21, which serves as the second powder quantity detection means. As shown in Figure 11, the control unit 110 determines whether or not it has detected that the powder container 10 is full of waste toner 13 based on the signal from the powder quantity sensor 21 (step S21). If fullness is detected (Yes in step S21), the process proceeds to step S22; if fullness is not detected (No in step S21), the determination in step S21 is repeated.

[0063] In step S22, the control unit 110 detects that the powder container 10 is full of waste toner 13 and then determines whether a predetermined grace period has elapsed. The grace period can be set by, for example, the number of printed pages or the operating time of the image forming apparatus 100. If the predetermined grace period has elapsed (Yes in step S22), the process proceeds to step S24; if the predetermined grace period has not elapsed (No in step S22), the process proceeds to step S23.

[0064] In step S23, the control unit 110 performs the first loading process. Specifically, the control unit 110 issues an instruction to replace the powder container 10 and returns the process to step S21. In step S24, the control unit 110 performs a second loading process. Specifically, the control unit 110 issues an instruction to replace the powder container 10 and sets the machine to a state where it will not accept new print jobs.

[0065] In the embodiment described above, the image forming apparatus 100 that forms an image on a recording medium comprises a powder container 10, a drive source 31, a first powder quantity detection means 112, and a powder quantity sensor 21 as a second powder quantity detection means. The powder container 10 is interchangeably provided to the image forming apparatus 100 and contains waste toner 13 as powder remaining after image formation. The drive source 31 drives a moving member 12 that moves the waste toner 13 within the powder container 10. The first powder quantity detection means 112 detects the amount of waste toner 13 in the powder container 10 based on a value relating to the load torque of the drive source 31. The powder quantity sensor 21 is of a different type from the first powder quantity detection means 112 and detects the amount of waste toner 13 in the powder container 10.

[0066] In this embodiment, the amount of waste toner 13 in the powder container 10 can be detected using two different types of means: a first powder quantity detection means 112 and a powder quantity sensor 21 as a second powder quantity detection means. Therefore, even if the powder quantity sensor 21 malfunctions, the amount of waste toner 13 in the powder container 10 can still be detected by the first powder quantity detection means 112. In other words, the occurrence of a situation where it is not possible to detect that the powder container 10 is full of waste toner 13 can be further reduced. Therefore, according to this embodiment, it is possible to more reliably suppress the overflow of waste toner 13 from the powder container 10 in the image forming apparatus 100. This also suppresses clogging of the waste toner path 90 connected to the powder container 10.

[0067] Furthermore, in this embodiment, the powder quantity sensor 21, which serves as the second powder quantity detection means, is an optical sensor. In this configuration, the amount of waste toner 13 in the powder container 10 can be detected more reliably with a simple configuration by using an optical sensor that optically detects the waste toner 13 in the powder container 10.

[0068] Furthermore, in this embodiment, the value relating to the load torque of the drive source 31 is determined from the value of the electrical input supplied to the drive source 31. In this configuration, since the value relating to the load torque of the drive source 31 is calculated using the value of the electrical input, there is no need to prepare a new sensor as the first powder quantity detection means 112. This helps to suppress cost increases and save space.

[0069] Furthermore, in this embodiment, the electrical input value used to calculate the load torque value of the drive source 31 is the current value. In this configuration, the configuration can be simplified by determining the load torque of the drive source 31 from the value of the current supplied to the drive source 31. It is also possible to use a voltage value as the electrical input value.

[0070] Furthermore, in this embodiment, a replacement instruction for the powder container 10 is issued based on the detected amount of waste toner 13 in the powder container 10. With this configuration, the powder container 10 can be appropriately replaced by issuing a replacement instruction when a full capacity of the powder container 10 is detected, thus making efficient use of the capacity of the powder container 10.

[0071] Furthermore, in this embodiment, the instruction to replace the powder container 10 is issued based on the detection result of the first powder quantity detection means 112 or the detection result of the powder quantity sensor 21, which is the second powder quantity detection means. In this configuration, the replacement instruction may be issued when a full load is detected based on the detection result of the first powder quantity detection means 112, or when a full load is detected based on the detection result of the powder quantity sensor 21. This makes it possible to replace the powder container 10 more reliably.

[0072] Furthermore, in this embodiment, the timing for issuing a replacement instruction for the powder container 10 is set to differ depending on whether the replacement instruction is issued based on the detection result of the first powder quantity detection means 112 or based on the detection result of the powder quantity sensor 21, which acts as a second powder quantity detection means. With this configuration, it is possible to set multiple timings for issuing a replacement instruction for the powder container 10, staggered according to the purpose. This makes it possible to issue a replacement instruction for the powder container 10 more accurately.

[0073] Furthermore, in this embodiment, the replacement instruction issued based on the detection result of the powder quantity sensor 21, which acts as the second powder quantity detection means, is set to be issued before the replacement instruction issued based on the detection result of the first powder quantity detection means 112. In this configuration, for example, under normal conditions, a replacement instruction can be issued based on the detection result of the powder quantity sensor 21, and under some abnormal conditions, a replacement instruction can be issued based on the detection result of the first powder quantity detection means 112. Here, some abnormal conditions include a malfunction of the powder quantity sensor 21, or when waste toner 13 accumulates in the powder container 10 in a way that avoids detection by the powder quantity sensor 21. The reason why full-load detection by the first powder quantity detection means 112 is performed after full-load detection by the powder quantity sensor 21 under normal conditions is that an increase in the load torque of the drive source 31 affects the lifespan of the drive mechanism 30, including the drive source 31. In particular, the value related to the load torque of the drive source 31 fluctuates due to variations in the drive source 31 itself and changes over time. Therefore, in order to prevent unintended premature replacement of the powder container 10, it is necessary to set a higher threshold value for the load torque of the drive source 31 for the replacement instruction, taking into account fluctuations.

[0074] Furthermore, in this embodiment, when an instruction to replace the powder container 10 is issued based on the detection result of the first powder quantity detection means 112, the system is set to a state where it will not accept new print jobs. In this configuration, when an instruction to replace the powder container 10 is issued based on the detection result of the first powder quantity detection means 112, the drive mechanism 30, such as the drive source 31, is already under a certain load, so it is possible to prevent it from being subjected to any further load.

[0075] Furthermore, in this embodiment, the state in which new print jobs are not accepted is released when the powder container 10 is replaced. The increase in load torque of the drive source 31 is reset when the powder container 10 is replaced. Therefore, in this embodiment, by releasing the prohibition on accepting new print jobs in conjunction with the replacement of the powder container 10, it becomes possible to execute new print jobs while reducing the load on the drive mechanism 30, such as the drive source 31.

[0076] Furthermore, in this embodiment, the value relating to the load torque of the drive source 31 is determined by the difference between the load torque of the drive source 31 measured in a defined interval and the current value relating to the load torque of the drive source 31. Since there are individual differences in the load torque value of the drive source 31 itself, it is desirable to have a mechanism to cancel out these individual differences. Therefore, in this embodiment, a base value relating to the load torque of the drive source 31 is measured in advance, and the difference between this and the current value is calculated and used, thereby preventing the drive source 31 from being affected by individual differences in itself.

[0077] Furthermore, in this embodiment, the base current value, which is a value related to the load torque of the drive source 31 measured over a defined interval, is updated at regular intervals. Since the value of the load torque of the drive source 31 may change over time over a long period, it is desirable to have a mechanism to cancel out the changes over time. Therefore, in this embodiment, by updating the base value at regular intervals, it is possible to avoid being affected by changes over time in the drive source 31.

[0078] Furthermore, in this embodiment, the fixed interval at which the base current value is updated is set by the number of printed sheets or the operating time of the image forming apparatus 100. With this configuration, the interval for updating the base value can be easily set to an interval corresponding to the time-dependent change of the drive source 31.

[0079] Furthermore, in this embodiment, the base current value, which is a value relating to the load torque of the drive source 31 measured over a defined period, is updated when the powder container 10 is replaced. When the powder container 10 is replaced, the amount of waste toner 13 in the powder container 10 decreases, and the drive mechanism 30, such as the moving member 12 inside the powder container 10, is also replaced, so the value of the load torque of the drive source 31 naturally changes. Therefore, in this embodiment, by updating the base value in accordance with the replacement of the powder container 10, it is possible to avoid being affected by the replacement of the powder container 10. Also, since the replacement of the powder container 10 cannot be recognized while the power supply of the image forming apparatus 100 is stopped, a configuration can be adopted in which the update of the base value is triggered by power-on.

[0080] Furthermore, in this embodiment, if the current load torque value of the drive source 31 falls below a certain value compared to the load torque value of the drive source 31 measured in a predetermined section, an instruction to replace the powder container 10 is issued. If the powder container 10 is not replaced, the amount of waste toner 13 in the powder container 10 will continue to increase, so the load torque value of the drive source 31 will normally rise. However, if the load torque value of the drive source 31 begins to decrease, there is a possibility that a malfunction such as damage has occurred in the drive mechanism 30. Therefore, in this embodiment, by issuing an instruction to replace the powder container 10 when the load torque value of the drive source 31 falls below a certain value, it is possible to quickly resolve the malfunction.

[0081] Furthermore, in this embodiment, if the current load torque value of the drive source 31 is small and an instruction to replace the powder container 10 is issued, the running print job is stopped and the system is set to not accept new print jobs. The problem anticipated here is when the transmission of driving force from the drive source 31 is interrupted due to damage to the moving member 12 that moves the waste toner 13. In this case, for example, if the moving member 12 that moves the waste toner 13 is damaged, there is a risk that the waste toner path 90 connected to the powder container 10 will become clogged very quickly. Therefore, in this embodiment, the running print job is stopped immediately and new print jobs are also disabled to prevent the damage from escalating.

[0082] Furthermore, in this embodiment, the cessation of ongoing print jobs and the inability to accept new print jobs are released when the powder container 10 is replaced. Replacing the powder container 10 resolves any malfunctions such as damage to the drive mechanism 30. Therefore, in this embodiment, by releasing the cessation of ongoing print jobs and the prohibition on accepting new print jobs in conjunction with the replacement of the powder container 10, malfunctions such as damage to the drive mechanism 30 are resolved, and print jobs become executable.

[0083] Furthermore, in this embodiment, the movable member 12 is rotatable, and the value relating to the load torque of the drive source 31 is determined based on the results of measurements taken multiple times during one rotation of the movable member 12. If the movable member 12 that moves the waste toner 13 in the powder container 10 is a rotatable member such as a screw, the value of the load torque increases or decreases during one rotation of the movable member 12. In this embodiment, a stable value can be obtained by taking several measurements during one rotation of the movable member 12 and determining the value relating to the load torque of the drive source 31 based on the results of multiple measurements, for example by performing an averaging process. It is also possible to obtain a stable value by applying a low-pass filter to the measured value of the load torque to cut out high-frequency components.

[0084] Furthermore, in this embodiment, the drive source 31 is connected to a movable member 12 provided inside the powder container 10 via a drive coupling part 32, and the drive coupling part 32 is disconnected when the load torque of the drive source 31 exceeds a predetermined value. In many image forming apparatuses 100, the drive source 31 is placed on the main body side, and only the minimum number of components of the drive mechanism 30 are placed on the powder container 10 side, which is discarded when replaced. In this embodiment, by configuring the drive coupling part 32 to be disconnected when a load torque exceeding a predetermined value is applied, the connection with the drive mechanism 30 on the main body side is severed, protecting the drive mechanism 30 on the main body side from damage. Here, the main body refers to the housing 101 and the main components installed inside the housing 101.

[0085] The drive coupling section 32 may have a first coupling section 33 on the drive source 31 side and a second coupling section 34 on the powder container 10 side, and the second coupling section 34 may be configured to have a weaker coupling strength than the first coupling section 33. In this configuration, when the drive source 31 is placed on the main body side of the image forming apparatus 100, the second coupling section 34 on the powder container 10 side is intentionally set to have a weaker strength than the first coupling section 33 on the drive source 31 side. Therefore, in the event of overload, the second coupling section 34, such as the coupling section of the movable member 12, will be damaged. This will sever the connection with the drive mechanism 30 on the main body side, protecting the drive mechanism 30 on the main body side from damage. In addition, by replacing the powder container 10, the damaged parts of the second coupling section 34 can be replaced one by one.

[0086] Although embodiments of the present invention have been described above, the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from its spirit. Furthermore, some of the configurations of the embodiments described above can be added, deleted, or replaced.

[0087] For example, multiple powder quantity sensors 21 may be provided. Furthermore, the powder quantity sensor 21 is not limited to an optical sensor; other sensors, such as magnetic sensors, may be used. Furthermore, although the image forming apparatus 100 is a tandem-type color image forming apparatus in the embodiment described above, it is not limited to this, and may, for example, be a drum-type image forming apparatus that supports black and white. [Explanation of Symbols]

[0088] 10 Powder container 12 Moving member 13. Waste toner (powder) 21 Powder quantity sensor (second powder quantity detection means) 31 Power source 32 Drive coupling section 33 1st connection part 34 2nd connection part 90 Toner Waste Route 100 Image forming apparatus 110 Control Unit 112 First powder quantity detection means S Paper (recording medium)

Claims

1. An image forming apparatus for forming an image on a recording medium, A powder container is provided interchangeably with the aforementioned image forming apparatus for containing powder remaining after image forming, A drive source for driving a moving member that moves powder within the powder container, A first powder quantity detection means detects the amount of powder in the powder container based on a value relating to the load torque of the drive source, A second powder quantity detection means, of a different type from the first powder quantity detection means, for detecting the amount of powder in the powder container, Equipped with, The drive source is connected to the movable member provided in the powder container via a drive coupling. The drive coupling portion has a first coupling portion on the drive source side and a second coupling portion on the powder container side. The second connecting portion has a lower connecting strength than the first connecting portion, in an image forming apparatus.

2. The image forming apparatus according to claim 1, wherein the second powder quantity detection means is an optical sensor.

3. The image forming apparatus according to claim 1, wherein the value relating to the load torque of the drive source is determined from the value of the electrical input supplied to the drive source.

4. The image forming apparatus according to claim 3, wherein the value of the electrical input is a current value.

5. The image forming apparatus according to claim 1, which issues an instruction to replace the powder container based on the detected amount of powder in the powder container.

6. The image forming apparatus according to claim 5, wherein the replacement instruction is issued based on the detection result by the first powder quantity detection means or the detection result by the second powder quantity detection means.

7. The image forming apparatus according to claim 6, wherein the timing of issuing the replacement instruction differs depending on whether the replacement instruction is issued based on the detection result by the first powder quantity detection means or based on the detection result by the second powder quantity detection means.

8. The image forming apparatus according to claim 7, wherein the replacement instruction issued based on the detection result by the second powder quantity detection means is issued before the replacement instruction issued based on the detection result by the first powder quantity detection means.

9. The image forming apparatus according to claim 6, wherein when the replacement instruction is issued based on the detection result by the first powder quantity detection means, the apparatus is set to a state in which it does not accept new print jobs.

10. The image forming apparatus according to claim 9, wherein the state in which the apparatus does not accept new print jobs is released when the powder container is replaced.

11. The image forming apparatus according to claim 1, wherein the value relating to the load torque of the drive source is determined by the difference between the value relating to the load torque of the drive source measured in a predetermined interval and the current value relating to the load torque of the drive source.

12. The image forming apparatus according to claim 11, wherein the value relating to the load torque of the drive source measured in the predetermined section is updated at regular intervals.

13. The image forming apparatus according to claim 12, wherein the aforementioned fixed interval is set by the number of printed sheets or the operating time of the image forming apparatus.

14. The value relating to the load torque of the drive source measured in the aforementioned defined section is the powder container capacity The image forming apparatus according to claim 11, which is updated when the device is replaced.

15. The image forming apparatus according to claim 11, wherein if the current load torque value of the drive source becomes less than or equal to a certain value than the value of the load torque of the drive source measured in the predetermined section, an instruction to replace the powder container is issued.

16. The image forming apparatus according to claim 15, wherein when an instruction is given to replace the powder container, the currently running print job is stopped and the apparatus is set to not accept new print jobs.

17. The image forming apparatus according to claim 16, wherein the state of stopping the running print job and the state of not accepting new print jobs is released when the powder container is replaced.

18. The aforementioned movable member is rotatable, The image forming apparatus according to claim 1, wherein the value relating to the load torque of the drive source is determined based on the results of measurements taken multiple times during one rotation of the moving member.

19. The drive source is connected to the movable member provided in the powder container via a drive coupling. The image forming apparatus according to claim 1, wherein the drive coupling is released when the load torque of the drive source exceeds a predetermined value.

20. A method used in an image forming apparatus, comprising: a powder container detachably provided to the image forming apparatus for containing powder remaining after image forming; and a drive source for driving a moving member for moving powder within the powder container, A first powder quantity detection step, which detects the amount of powder in the powder container based on a value relating to the load torque of the drive source, The method includes a second powder quantity detection step of a different type from the first powder quantity detection step, which detects the amount of powder in the powder container, The drive source is connected to the movable member provided in the powder container via a drive coupling. The drive coupling portion has a first coupling portion on the drive source side and a second coupling portion on the powder container side. A method wherein the second connecting portion has a lower connecting strength than the first connecting portion.

21. A program for controlling an image forming apparatus, comprising: a powder container that is interchangeably provided to the image forming apparatus and contains powder remaining after image forming; and a drive source that drives a moving member for moving the powder within the powder container, A first powder quantity detection procedure for detecting the amount of powder in the powder container based on a value relating to the load torque of the drive source, The computer is instructed to execute a second powder quantity detection procedure, which is of a different type from the first powder quantity detection procedure, for detecting the amount of powder in the powder container. The drive source is connected to the movable member provided in the powder container via a drive coupling. The drive coupling portion has a first coupling portion on the drive source side and a second coupling portion on the powder container side. The second connecting portion has a lower connecting strength than the first connecting portion.

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