Fixing Roller Elastic-Layer Life Tracking in Induction Fusers
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Solution Overview
Problem
The elastic layer of a fixing roller in an image forming apparatus using induction heating deteriorates due to heat accumulation in the metal base, leading to a loss of elasticity and reduced lifetime, which is difficult to predict accurately.
Innovation Solution
A control system calculates the cumulative electric power supply time to the induction heating portion, using a lifetime prediction formula to determine the remaining lifetime of the fixing roller's elastic layer, and indicates this on a gauge, ensuring accurate prediction by excluding non-contributory power supply times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If induction heating is used to heat the fixing belt, then heating efficiency is improved, but the metal base of the fixing roller accumulates heat causing elastic layer deterioration
Solution Approach 1:
The control portion calculates the cumulative electric power supply time in advance and predicts the remaining lifetime of the elastic layer before actual failure occurs. This allows proactive maintenance scheduling and prevents sudden failures by estimating deterioration based on accumulated thermal exposure history.
Solution Approach 2:
The system implements a feedback mechanism where the control portion continuously monitors the cumulative power supply time to the induction heating portion, calculates the corresponding thermal exposure of the metal base, and updates the remaining lifetime prediction of the elastic layer accordingly. This closed-loop monitoring enables dynamic assessment of component health.
2Loss of time
If cumulative power supply time is tracked for lifetime prediction, then maintenance timing is optimized, but system complexity increases
Solution Approach 1:
The control portion performs multiple functions: it controls the image forming portion, the fixing device, and the fixing voltage power supply, while simultaneously calculating the cumulative electric power supply time and predicting the remaining lifetime of the elastic layer. By integrating these functions into a single control unit, the system avoids adding separate dedicated hardware for monitoring, thus minimizing complexity increase.
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
Accurately predicts the remaining lifetime of the fixing roller's elastic layer, allowing for proactive maintenance and minimizing downtime by indicating the need for a replacement before failure, thus maintaining printing efficiency.
Implementation Method 1
a fixing device which includes a fixing member having a fixing roller or a fixing belt (i.e., heated rotary member) and a pressing roller (pressing rotary member) in pressed contact with each other. The fixing device of a belt fixing type using the fixing belt employs the induction heating method in which a heating layer of the fixing belt is heated by electromagnetic induction.
Implementation Method 2
The fixing device of a belt fixing type using the fixing belt employs the induction heating method in which a heating layer of the fixing belt is heated by electromagnetic induction.
Implementation Method 3
If the heat accumulates, it surpasses the heat resistance of the elastic layer, which thus gradually loses its elasticity and deteriorates. The time for the elastic layer to deteriorate to become unusable depends on the temperature of the metal base and the cumulative heated time.
Data Source
AI summary
An image forming apparatus includes an image forming portion, a fixing device, a fixing voltage power supply, and a control portion. The fixing device includes an endless fixing belt, a fixing roller inside it with a metal base and an elastic layer on its outer circumference, a pressing roller in pressed contact with the fixing roller across the fixing belt, and an induction heating portion heating the fixing belt. The control portion calculates, as a cumulative electric power supply time, the cumulative value of the supply time of a predetermined electric power supplied to the induction heating portion, and determines the remaining lifetime of the fixing roller by comparing, as its lifetime, the failure time y [min] of the elastic layer, calculated with the supplied electric power substituted in the damage electric power x [W] in lifetime prediction formula (1), with the cumulative electric power supply time.