Cleaning Blade Deterioration Estimation via Developing Current Ratio
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Solution Overview
Problem
Existing image forming apparatuses fail to accurately detect the deterioration of the cleaning blade, leading to uneven toner distribution and increased toner consumption due to the inability to assess the slipperiness of the blade effectively.
Innovation Solution
The apparatus includes a control device with a processor that measures and calculates the developing current ratio by changing the DC bias voltage, allowing it to estimate the deterioration status of the cleaning blade based on the current ratio, thereby improving the detection of slipperiness and toner distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the cleaning blade is used continuously without monitoring, then the device complexity is reduced, but the manufacturing precision deteriorates due to uneven toner distribution
Solution Approach 1:
The patent replaces mechanical inspection methods with electrical measurement. By measuring the developing current between the developing agent carrier and image carrier, the system detects cleaning blade deterioration status without requiring physical contact or complex mechanical sensors, thus maintaining manufacturing precision while avoiding increased device complexity
Solution Approach 2:
The system uses the existing developing current measurement infrastructure to simultaneously monitor cleaning blade status. The developing current, already measured for image formation control, is repurposed to detect blade deterioration, allowing the system to self-diagnose without adding separate monitoring hardware
2Loss of substance
If the cleaning blade deterioration is not detected, then the loss of time is reduced, but the loss of substance increases due to increased toner consumption
Solution Approach 1:
The system continuously monitors the developing current and compares it against reference values to detect cleaning blade deterioration. When deterioration is detected through current ratio changes, the system provides feedback to trigger maintenance actions, preventing excessive toner consumption while enabling timely intervention to minimize maintenance time
Solution Approach 2:
The system detects cleaning blade deterioration before it causes significant toner distribution problems by continuously monitoring developing current variations. This preliminary detection allows maintenance to be performed proactively, preventing both excessive toner consumption and unnecessary frequent maintenance
3Measurement precision
If the DC bias is changed to measure current ratio, then the measurement precision is improved, but the use of energy increases due to multiple bias voltage applications
Solution Approach 1:
The system applies multiple DC bias voltages (first DC bias and second DC bias) to obtain sufficient measurement precision for detecting cleaning blade deterioration. By using partial excessive action (applying more bias variations than strictly minimum), the system achieves reliable detection of current ratio changes that indicate blade status, with the energy cost being acceptable given the low power consumption of the measurement process
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 enables the image forming apparatus to accurately estimate the cleaning blade's deterioration status, ensuring uniform toner distribution and reducing toner consumption by monitoring the current ratio and providing timely alerts for maintenance.
Implementation Method 1
The voltage applier applies a bias voltage including a DC bias and an AC bias, to the developing agent carrier, to cause the toner to migrate from the developing agent carrier to the image carrier
Implementation Method 2
The current detector measures developing current flowing between the developing agent carrier and the image carrier
Data Source
AI summary
An image forming apparatus includes an image carrier, a developing device, a voltage applier, a current detector, a cleaning blade, and a control device. The control device acts as a measurer and an estimator. The measurer changes the DC bias to a first value and a second value, and acquires a first magnitude of the developing current corresponding to the first value, and a second magnitude of the developing current corresponding to the second value, from the current detector. The estimator calculates a current ratio between the first magnitude and the second magnitude, and estimates deterioration status of the cleaning blade, according to the value of the current ratio.