Gear Failure Detection via Toner Density Variation

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Solution Overview

Problem

Existing electrophotographic image forming apparatuses face challenges in timely detection of gear failure due to aging deterioration, as current methods based on drive current analysis often fail to provide early warning, leading to inadequate maintenance preparation.

Innovation Solution

The apparatus includes a formation processing unit that forms a to-be-detected toner image with specific density, an acquisition processing unit that measures the density variation width, and a determination processing unit that determines the gear failure timing based on this variation, allowing for earlier detection of gear failure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If drive current analysis is used to detect gear failure, then the detection method is simple, but the detection timing is delayed and fails to provide early warning

Engineering Contradiction:

Improvegear failure detection accuracyVSAvoiddetection timing

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Instead of detecting gear failure through its direct effect on drive current, the invention inverts the detection approach by measuring the indirect effect on toner image density. The gear's rotational speed variations cause density variations in the toner image, which serves as an earlier and more sensitive indicator of gear deterioration than drive current changes.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention introduces an intermediary measurement mechanism - the toner image density - that mediates between the gear's mechanical state and the detection system. This intermediary provides a more sensitive and earlier indication of gear failure than direct electrical measurements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of time

If toner image density measurement is used to detect gear failure, then early detection is enabled, but additional processing steps are required

Engineering Contradiction:

Improvedetection timingVSAvoiddetection system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The invention leverages the existing toner image formation process and density measurement capability, which are already integral parts of the image forming apparatus. By using this multi-functional existing system for dual purposes (image formation and gear monitoring), the invention avoids adding complex dedicated detection hardware.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its own operational output (the toner image it produces) as the sensing medium for detecting gear failure. The apparatus essentially monitors itself by measuring the quality of its own output, eliminating the need for separate external sensing systems.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12044995B2Image forming apparatus capable of determining failure timing of a gear used therein, and determining method of the failure timing

Publication Date: 2024.07.23 KYOCERA DOCUMENT SOLUTIONS INC

AI summary

An image forming apparatus includes: a gear that transmits a drive force, which is supplied from a drive unit, to a photosensitive drum; a formation processing unit that, at arrival of each of specific formation timings, uses the photosensitive drum thereby to form a to-be-detected toner image that is based on a to-be-detected image having a specific density; an acquisition processing unit that acquires a variation width of a density in the to-be-detected toner image formed by the formation processing unit; and a determination processing unit that determines a failure timing of the gear based on the variation width for each of the formation timings.