Process Cartridge Initialization to Prevent Motor Overload
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Solution Overview
Problem
Existing image forming apparatuses require large torque for motors to drive multiple process cartridges, especially when new cartridges are installed, and toner hardening can prevent proper operation due to increased load.
Innovation Solution
An image forming apparatus with a controller that performs initial operations in two states: one with all cartridges mounted and another with fewer cartridges, detecting overload and instructing the user to remove specific cartridges to reduce motor load, ensuring proper operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single motor drives multiple process cartridges simultaneously, then the device complexity is reduced, but the motor requires large torque especially when new cartridges are installed
Solution Approach 1:
The patent divides the initial operation into two phases: first operating the motor with fewer cartridges (one or two) to reduce torque requirements, then adding remaining cartridges after the initial operation completes. This temporal segmentation allows the motor to handle the load in manageable stages rather than all at once.
Solution Approach 2:
The patent performs preliminary action by completing the initial operation with a subset of cartridges before adding the remaining ones. This ensures that critical initialization tasks are completed when motor load is minimal, preventing torque-related failures during the most critical setup phase.
2Productivity
If all process cartridges are driven simultaneously during initial operation, then the productivity is improved, but toner hardening can prevent proper operation due to increased load
Solution Approach 1:
The patent segments the cartridge set into two groups: a first group (one or two cartridges) that undergoes initial operation, and a second group (remaining cartridges) that is added afterward. This segmentation ensures that toner in newly installed cartridges doesn't harden under excessive motor load, maintaining reliability while still achieving efficient setup.
Solution Approach 2:
The patent applies partial action by completing only a portion of the initial operation (with one or two cartridges) before adding remaining cartridges. This partial completion strategy balances productivity and reliability by performing critical operations when load is minimal, then adding remaining functionality afterward.
3Reliability
If the motor size is increased to handle all cartridges, then the reliability is improved, but the device complexity and cost increase
Solution Approach 1:
The patent applies a dynamic operational strategy where the number of driven cartridges changes over time: starting with one or two cartridges during initial operation, then adding remaining cartridges afterward. This dynamic approach allows a smaller motor to achieve the reliability of a larger motor by adapting the load conditions to match motor capabilities.
Data Source
AI summary
An image forming apparatus on which cartridges are dismountably mounted includes a motor and driving members. A controller performs an initial operation in which the driving members are driven by the motor in a state in which a new cartridge is mounted on the casing before performing image forming operation and performs a resolving operation to stop the initial operation when an overload state of the motor is detected during performing the initial operation in a state in which at least two new cartridges are mounted on a casing, to determine a target cartridge, and to display to be taken out the target cartridge from the casing. The controller determines the target cartridge so that at least one new cartridge is left in the casing in a case in which the target cartridge is taken out from the casing.