Dual-Sensor Ink Level Detection for Continuous Printing
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Solution Overview
Problem
Existing image forming apparatuses with liquid discharge recording types face challenges in maintaining optimal ink supply to the sub-tank during printing, leading to interruptions and reduced printing speed due to imprecise detection of ink levels and negative pressure fluctuations.
Innovation Solution
The apparatus employs a dual-sensor system where the first sensor on the carriage detects the displacement member's position during printing, and the second sensor on the body of the apparatus confirms the fully filling state, allowing continuous ink supply without interrupting the printing process by calculating the differential supply amount based on the displacement change.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single sensor on the carriage detects ink level, then the structure is simple, but printing must be interrupted to confirm full filling state
Solution Approach 1:
The ink level detection function is segmented into two parts: a first sensor on the carriage for real-time monitoring during printing, and a second sensor on the body for confirming full filling state. This segmentation allows continuous printing while maintaining accurate ink level detection without requiring complete carriage stops.
Solution Approach 2:
The first sensor detects the displacement member position preliminarily during printing to determine when ink supply is needed, allowing the system to prepare for ink supply without interrupting the printing process, thus maintaining productivity.
2Measurement precision
If ink supply is performed only when carriage is at detection position, then detection is accurate, but printing speed decreases due to interruptions
Solution Approach 1:
The first sensor enables continuous ink level monitoring during printing operations, allowing the system to maintain accurate detection without stopping the carriage. This ensures both measurement precision and continuous printing productivity.
3Device complexity
If negative pressure is not maintained properly, then ink supply is simple, but ink seeping or dripping occurs from nozzles
Solution Approach 1:
The dual-sensor system provides feedback on the displacement member position, which reflects the ink level and negative pressure state in the sub-tank. This feedback enables the control system to adjust ink supply to maintain optimal negative pressure, preventing ink seeping or dripping while ensuring reliable ink discharge.
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 approach enables continuous ink supply to the sub-tank during printing, maintaining optimal negative pressure and improving printing speed and efficiency by avoiding interruptions and errors in ink detection.
Implementation Method 1
a negative pressure creating part that includes a resilient member that gives such force to the flexible member to cause it to move outward
Implementation Method 2
The sub-tank is provided with a displacement member (also referred to as a detection member or a detection filler) which changes a position itself as a position of the flexible member changes
Implementation Method 3
a first photo sensor fixed to the carriage for detecting the position of the displacement member
Data Source
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AI summary
In an image forming apparatus, a first detection part and a second detection part, each for detecting a position of a displacement member that changes its position according to a remaining amount of liquid in a sub-tank, are provided to a carriage carrying the sub-tank and a recording head, and a body of the image forming apparatus, respectively. A first position is a position of the displacement member detected by the first detection part such that the remaining amount of liquid in the sub-tank is smaller than that at a second position detected by the second detection part. The liquid is supplied to the sub-tank of a differential supply amount, corresponding to a displacement amount of the displacement member between a position detected by the first detection part and a position detected by the second detection part, after the first detection part detects the displacement member.