Developer Replenishing Unit Predicts Toner Consumption
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Solution Overview
Problem
Image density decreases due to toner consumption by potential differences between the image carrier and developer carrier at the start or end of image forming operations, leading to inefficient toner replenishment in image forming apparatuses.
Innovation Solution
An image forming apparatus with a developer replenishing unit that predicts and anticipates the toner consumption at the start or end of image formation, proactively replenishing the developer to maintain image density, using a controller to calculate and execute toner replenishment based on image formation data and environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If toner replenishment is performed based on standard consumption rates, then normal image formation is maintained, but image density decreases at the start or end of operations due to unexpected toner consumption
Solution Approach 1:
The system performs preliminary action by predicting toner consumption at start/end of image formation in advance and replenishing toner before the actual consumption occurs. The controller calculates predicted consumption amounts based on potential differences and replenishes toner proactively, preventing image density decreases rather than reacting after they occur.
2Reliability
If toner replenishment is performed continuously, then image density is maintained, but toner is wasted during periods when no image formation occurs
Solution Approach 1:
The system implements periodic action by performing toner replenishment only at specific intervals - at the start or end of image formation operations when consumption is predicted. The controller determines replenishment timing based on operational cycles and potential difference conditions, avoiding continuous replenishment and preventing toner waste during non-operational periods.
3Reliability
If toner replenishment amount is increased to prevent density decrease, then image quality is improved, but excessive toner is supplied during normal operations
Solution Approach 1:
The system applies local quality by providing differentiated toner replenishment - extra toner is supplied only at specific locations in time (start/end of image formation) when consumption is predicted, rather than uniformly increasing replenishment amounts during all operations. The controller calculates and applies localized replenishment amounts based on specific operational conditions.
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
Prevents decreases in image density by ensuring adequate toner supply during image formation, maintaining consistent image quality despite toner consumption at the start or end of operations.
Implementation Method 1
toner consumed by adhering to a surface of an image carrier by a potential difference between the image carrier and a developer carrier
Data Source
AI summary
An image forming apparatus includes: an image carrier configured to carry an image; a developing unit configured to develop the image carried by the image carrier with a developer; and a developer replenishing unit configured to supply the developer to the developing unit, the developer replenishing unit being configured to predict, in advance, an amount of developer consumed by the image carrier at a start or an end of image formation apart from developer consumed in the image formation, to replenish the predicted amount of the developer.