Belt Drive Encoder Disk Axial Alignment for Speed Detection

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Solution Overview

Problem

Current multicolor image forming apparatuses face challenges in accurately stabilizing the rotational speeds of photosensitive drums due to insufficient rotation sensor coverage, leading to potential misalignment and increased production costs with dual optical sensors for axis deviation compensation.

Innovation Solution

A belt drive device with a metallic flat belt and a speed detecting device featuring an encoder disk and a single optical sensor, securely aligned with the driven pulley, accurately detects the rotational speed of the photosensitive drum, eliminating the need for additional attachment members and reducing production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single optical sensor is used to detect rotational speed, then production costs are reduced and device complexity is simplified, but measurement accuracy may be insufficient due to potential axis deviation

Engineering Contradiction:

Improvenumber of optical sensorsVSAvoidrotational speed detection accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The encoder disk serves as an intermediary component that is mounted on the driven pulley rather than directly on the photosensitive drum. This intermediary arrangement allows the single optical sensor to accurately read the optical pattern on the encoder disk, which rotates in sync with the driven pulley, thereby achieving precise rotational speed detection without requiring dual sensors or direct mounting on the drum axis

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces the mechanical direct-mounting system (where the encoder disk would be mounted directly on the drum axis) with an optical reading system. The optical sensor reads the optical pattern on the encoder disk that is mounted on the driven pulley, substituting mechanical alignment requirements with optical detection, thereby enabling accurate measurement with a single sensor

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If the encoder disk is secured directly to the photosensitive drum, then rotational speed detection is achieved, but additional attachment members increase production costs and device complexity

Engineering Contradiction:

Improverotational speed detectionVSAvoidnumber of attachment members

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The encoder disk is merged with the driven pulley by securing it directly to the driven pulley's rotation axis. This combination eliminates the need for separate attachment members between the encoder disk and the drive system, as the driven pulley itself serves as the mounting structure. The encoder disk, driven pulley, and photosensitive drum are functionally integrated through the belt drive mechanism

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The driven pulley serves multiple functions: it transmits drive force from the drive belt to rotate the photosensitive drum, and it simultaneously serves as the mounting structure for the encoder disk. This multi-functionality eliminates the need for dedicated attachment members, reducing part count and production costs while maintaining accurate rotational speed detection

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution ensures accurate rotational speed detection of the photosensitive drum, reduces axis deviation, and decreases production costs by utilizing a single optical sensor, while maintaining consistent tension and efficient drive force transmission, thereby stabilizing the image formation process.

Implementation Method 1

The optical sensor is capable of reading the optical pattern. The speed detecting device detects a rotational speed of the driven shaft based on a result of the optical sensor having read the optical pattern.

Methodology Applied

Scientific EffectOptical detection: Photoelectric Effect

Data Source

PatentUS12055883B2Belt drive device with encoder disk secured to driven pulley and image forming apparatus

Publication Date: 2024.08.06 KYOCERA DOCUMENT SOLUTIONS INC

AI summary

A belt drive device includes a drive source, a drive pulley, a driven shaft, a driven pulley, a belt, and a speed detecting device. The drive pulley is rotated about an axis thereof by the drive source. The driven shaft is rotatable about an axis thereof. The driven pulley is secured to and in axial alignment with the driven shaft. The belt is annularly formed of a metallic flat belt and mounted around the drive pulley and the driven pulley. The speed detecting device includes an encoder disk and a single optical sensor. The encoder disk has an optical pattern formed thereon. The optical sensor reads the optical pattern. The speed detecting device detects a rotational speed of the driven shaft based on a result of the optical sensor having read the optical pattern. The encoder disk is secured to and in axial alignment with the driven pulley.