Developer Supply Threshold Adjustment in Image Forming Apparatus
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Solution Overview
Problem
Existing image forming apparatuses wastefully dispose of developer remaining in the developing device due to supplying a predetermined amount without considering the service life of the device, leading to unused toner being discarded.
Innovation Solution
An image forming apparatus with a developing device, developer box, and transporter, which calculates the remaining developer amount using a sensor and adjusts the threshold for developer supply based on the device's service life, ensuring efficient use and minimizing waste by transporting developer only when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a predetermined amount of developer is supplied whenever integrated developer consumption exceeds a threshold, then the developer supply mechanism is simple and reliable, but developer waste increases when the developing device reaches end of service life
Solution Approach 1:
The patent applies dynamics by making the remaining amount threshold variable rather than fixed. The controller dynamically adjusts the threshold based on the counter value that tracks developing device usage. When the counter value is below a first threshold, a first remaining amount threshold is used; when the counter value reaches or exceeds the first threshold, a second remaining amount threshold (lower than the first) is applied. This dynamic adjustment ensures developer is supplied adequately during the device service life while preventing waste when the device is nearing end-of-life.
2Ease of operation
If developer is supplied based on integrated consumption without considering service life, then the supply timing is straightforward, but resource efficiency deteriorates due to unused toner disposal
Solution Approach 1:
The patent implements feedback by continuously monitoring the counter value that records developing device usage and using this information to adjust the remaining amount threshold. The controller receives feedback from the counter about device service life status and modifies the developer supply decision accordingly. This feedback mechanism maintains ease of operation while significantly improving resource efficiency by preventing the disposal of unused developer when the device is nearing end-of-life.
Solution Approach 2:
The patent applies parameter changes by modifying the remaining amount threshold parameter based on the counter value. The system transitions between two parameter states: a first remaining amount threshold when the counter value is below a first threshold, and a second remaining amount threshold when the counter value reaches or exceeds the first threshold. This parameter change strategy optimizes resource efficiency while maintaining operational simplicity.
Data Source
AI summary
An image forming apparatus includes a controller configured to, each time a development roller of a developing device rotates by a particular rotational amount, increment a counter value stored in a storage, calculate a remaining amount of developer in the developing device, when the counter value is less than a first value, setting a remaining amount threshold to a first threshold, whereas, when the counter value is equal to or more than a second value, setting the remaining amount threshold to a second threshold, the second value being equal to or more than the first value, the second threshold being less than the first threshold, and when the calculated remaining amount is less than the set remaining amount threshold, control a transporter to transport developer stored in a developer box to the developing device.