Corotron Lead Shaft Torque Reduction via Spring Cushioning
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Solution Overview
Problem
Existing corona-charging mechanisms in photocopiers face high torque issues during power on/off and paper jam conditions, leading to motor gear breakage and increased maintenance costs due to inefficient cleaning cycles and contamination, resulting in print quality defects and customer dissatisfaction.
Innovation Solution
The implementation of a lead shaft with reduced windings by 2-10% and the addition of springs at each terminal end to alleviate torque stress, combined with a plastic injection molding of the drive shaft to reduce costs and prevent motor damage, enhances the auto-cleaning mechanism for corona chargers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the lead shaft windings are reduced in length by 2-10%, then torque-related failures and motor gear breakage are reduced, but the cleaning cycle time may be affected
Solution Approach 1:
The patent extracts the harmful excessive windings from the lead shaft, reducing the winding length by 2-10% to eliminate the source of high torque conditions that cause motor gear breakage during power on/off and paper jam situations
Solution Approach 2:
The patent adds springs at terminal portions of the lead shaft that预先 engage with the holder before the shaft reaches the end of its travel, cushioning the reversal action and preventing high torque spikes before they can occur
2Reliability
If springs are added at terminal portions of the lead shaft, then torque stress is reduced and motor damage is prevented, but device complexity increases
Solution Approach 1:
The patent applies beforehand cushioning by installing springs at the terminal portions of the lead shaft that engage with the holder before the shaft completes its travel. These springs cushion the reversal action, absorbing torque spikes and preventing motor gear breakage during power on/off and paper jam conditions
3Ease of manufacture
If plastic injection molding is used for the drive shaft instead of metal, then manufacturing cost is reduced by over 20%, but strength and durability may be compromised
Solution Approach 1:
The patent changes the material parameter of the lead shaft from metal to plastic through injection molding, reducing manufacturing cost by over 20% while maintaining sufficient strength for the application through proper material selection and design
Solution Approach 2:
The patent uses plastic material for the lead shaft, which can be considered a composite material solution that provides adequate strength, corrosion resistance, and cost-effectiveness for the corona cleaner application
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 effectively reduces torque-related failures, extends motor life, and decreases maintenance needs, improving print quality and reducing customer dissatisfaction while offering significant cost savings through plastic molding.
Implementation Method 1
two springs are located at each terminal portion of the lead shaft. This provides the engagement of the holder 6 to the windings when motor is reversed
Implementation Method 2
These windings, because of their length, cause in part the torque problems above addressed since they are along the total length of the shaft
Data Source
AI summary
High torque causing machine failures and motor damage are corrected by the embodiments of this invention. Springs are put on both ends of the lead shaft and the windings around the lead shaft are reduced to substantially reduce the torque created during a power on-power off situation in addition to during normal operations.