Fixing Rotator Heating Control for Rapid Warm-Up
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Solution Overview
Problem
Existing image forming apparatuses face challenges in efficiently controlling the temperature of the fixing rotator to ensure consistent and high-quality image fixation, particularly due to the limitations of traditional PID controllers in quickly responding to changes in sheet type and thickness during printing.
Innovation Solution
The implementation of a controller with primary and secondary heating control portions, along with a switch portion, which adjusts the power supplied to the heater based on detected temperature and sheet type, allowing for dynamic switching between heating modes without altering the target temperature, thereby ensuring efficient heat management and image fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a traditional PID controller is used to control the heater temperature, then the control system is simple and stable, but the response speed to changes in sheet type and thickness is slow
Solution Approach 1:
The heating control is divided into two distinct modes: primary heating mode for rapid temperature increase and secondary heating mode for precise temperature maintenance. This segmentation allows the system to optimize response speed during warm-up while maintaining stability during operation, resolving the contradiction between fast response and simple control.
Solution Approach 2:
The controller dynamically switches between primary and secondary heating modes based on the operational state (warm-up phase vs. steady-state operation). This dynamic adjustment enables the system to achieve fast response during temperature rise while maintaining simple and stable control during normal operation, effectively resolving the speed-complexity contradiction.
2Reliability
If high power is continuously supplied to the heater to maintain temperature, then the fixing rotator temperature stability is improved, but the energy consumption increases
Solution Approach 1:
The controller applies high power periodically during the primary heating phase to rapidly reach target temperature, then switches to low-power periodic control during the secondary heating phase to maintain temperature. This periodic action pattern ensures temperature stability while minimizing energy consumption during steady-state operation.
Solution Approach 2:
The controller changes the power supply parameter dynamically: high power during warm-up phase to quickly establish temperature stability, then transitions to low power during operation phase to maintain stability with reduced energy consumption. This parameter change resolves the contradiction between reliability and energy use.
3Loss of time
If the heater power is rapidly increased to heat the fixing rotator quickly, then the warm-up time is reduced, but the temperature control precision deteriorates
Solution Approach 1:
The heating process is segmented into two phases: primary heating with high power for rapid warm-up (accepting lower precision), and secondary heating with low power for precise temperature control. This segmentation allows the system to achieve fast warm-up while maintaining high temperature control precision during operation.
Solution Approach 2:
The controller dynamically adjusts power level based on operational phase: high power during warm-up to minimize time loss, then transitions to low power for precise temperature maintenance. This dynamic adjustment resolves the contradiction between reducing warm-up time and maintaining temperature control precision.
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 enables rapid heating of the fixing rotator, maintaining consistent temperature and improving image quality while reducing energy consumption, especially in devices with thin fixing belts, by dynamically adjusting power based on detected conditions.
Implementation Method 1
a heater disposed opposite the fixing rotator to heat the fixing rotator
Implementation Method 2
A temperature detector is disposed opposite the fixing rotator to detect a temperature of the fixing rotator
Implementation Method 3
the fixing rotator and the opposed rotator apply heat and pressure to the recording medium, melting and fixing the toner image on the recording medium
Data Source
AI summary
An image forming apparatus includes a controller including a primary heating control portion that determines a first amount of power supplied to a heater based on a temperature of a fixing rotator detected by a temperature detector and controls the heater to perform a primary heating to heat the fixing rotator with the first amount of power, a secondary heating control portion that controls the heater to perform a secondary heating to heat the fixing rotator with a preset second amount of power, and a switch portion that controls the heater to switch between the primary heating and the secondary heating during an identical print job without changing a target temperature of the fixing rotator.