Coating Roller Idle Rotation for Stable Sheet Coating
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Solution Overview
Problem
Existing image forming systems face issues with inconsistent coating liquid application and quality due to residual coating liquid adhering to rollers during power-off or liquid deterioration, leading to variations in coating amounts and image quality.
Innovation Solution
The system includes a liquid level detector to initiate idle rotation of the coating and pressure rollers when the liquid level falls below a non-supply position during power-off, and a timer to detect liquid deterioration, ensuring controlled draining and recycling of coating liquid to maintain consistent application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the coating device is powered off without idle rotation, then power consumption is reduced and operation is simplified, but coating liquid adheres to the rollers and becomes fixed, causing inconsistent coating application and quality variations
Solution Approach 1:
The system performs idle rotation of the coating roller and pressure roller before power-off to remove adhering coating liquid. This preliminary action prevents the coating liquid from fixing to the rollers during storage, thereby maintaining coating consistency without requiring complex continuous monitoring or intervention systems.
2Manufacturing precision
If idle rotation is performed continuously, then coating liquid is prevented from adhering to rollers, but energy consumption increases and operational complexity increases
Solution Approach 1:
Instead of continuous idle rotation, the system implements periodic idle rotation specifically during power-off periods. The controller detects power-off state and initiates idle rotation only when necessary, reducing energy consumption while still preventing coating liquid from adhering to the rollers during storage periods.
3Device complexity
If the pressure roller remains separated from the coating roller, then the structure is simple and operation is easy, but coating liquid can adhere to the coating roller surface
Solution Approach 1:
The system performs preliminary idle rotation of the coating roller and pressure roller before power-off to remove adhering coating liquid. This action is taken regardless of the roller contact state, ensuring coating consistency while maintaining structural simplicity.
4Ease of operation
If coating liquid is not drained properly, then the system is simple to operate, but liquid deterioration occurs leading to quality variations
Solution Approach 1:
The liquid level detector provides feedback to the controller about the coating liquid level in the reservoir. When the liquid level falls below a predetermined level, the controller automatically activates the drain unit to remove excess coating liquid. This feedback mechanism ensures proper liquid level management and prevents deterioration without requiring complex manual intervention.
Data Source
AI summary
A coating device includes a reservoir to store a coating liquid, a coating roller to coat a sheet with the coating liquid, a pressure roller to contact the coating roller, a separator to bring and separate the pressure roller into contact with and from the coating roller, a supply unit to supply the coating liquid to the reservoir, a drain unit to drain the coating liquid from the reservoir, a liquid level detector to detect that a liquid level of the coating liquid is below a non-supply position, and circuitry. The circuitry controls the drain unit to drain the coating liquid after a power-off of the coating device, controls the separator to bring the pressure roller into contact with the coating roller after a detection of the liquid level below the non-supply position, and rotate the pressure roller and the coating roller for a predetermined time as an idle rotation.