Heater Power Control for Booklet Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing image forming apparatuses face challenges in managing power consumption when manufacturing booklets, as the time required to reduce power to the fixing heater is short, leading to increased time in forming toner images due to longer heating times for adhesive toner-based binding, which can exceed standard current limits.
Innovation Solution
An image forming apparatus with a control circuit that adjusts power supplied to both the fixing and bonding heaters based on detected inlet current, ensuring the current does not exceed rated values, thereby optimizing power distribution and reducing print time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If power supplied to the fixing heater is reduced to comply with current limits, then current consumption is controlled within standard values, but the time required to raise the heater temperature to target temperature increases
Solution Approach 1:
The control circuit starts reducing power to the fixing heater in advance before the booklet manufacturing process begins. This preliminary action ensures that when the second heater operates and current limits are approached, the fixing heater is already at a lower power state, preventing excessive current consumption while minimizing impact on image formation time
Solution Approach 2:
The control circuit dynamically adjusts the power supplied to the fixing heater based on the operational state of the booklet manufacturing unit. Power reduction is implemented selectively during periods when the second heater is operating, rather than maintaining a fixed reduced power level, thus balancing current consumption control with temperature maintenance needs
2Productivity
If power supplied to the second heater for booklet manufacturing is increased, then booklet manufacturing efficiency is improved, but the inlet current exceeds the rated value
Solution Approach 1:
The control circuit applies different power control strategies to different heaters based on their specific operational requirements. The second heater receives full power during booklet manufacturing operations to maintain high productivity, while the fixing heater receives reduced power during the same period. This localized power management allows the system to meet current limits without compromising booklet manufacturing efficiency
Solution Approach 2:
The control circuit continuously monitors the inlet current and dynamically adjusts the power distribution between the fixing heater and second heater. When inlet current approaches the rated value during second heater operation, the control circuit automatically reduces fixing heater power, creating a feedback loop that maintains current within limits while preserving booklet manufacturing capability
3Quantity of substance
If the power supplied to the fixing heater is reduced during booklet manufacturing, then current limits are maintained, but the image formation time increases
Solution Approach 1:
The control circuit implements periodic power reduction to the fixing heater that is synchronized with the booklet manufacturing cycle. Power is reduced only during specific periods when the second heater is operating and current limits are a concern, while maintaining normal power levels during image formation periods, thus minimizing the impact on image formation speed while still complying with current limits
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 effectively manages power consumption, preventing excessive current usage while maintaining print efficiency by dynamically controlling power to both heaters, ensuring the image forming process meets standard current limits without increasing print time.
Implementation Method 1
a fixing unit including a first heater that fixes the image to the sheet
Implementation Method 2
a booklet manufacturing unit that manufactures a booklet by heating a plurality of sheets that have passed through the fixing unit using a second heater and bonding together the plurality of sheets
Data Source
AI summary
An image forming unit forms an image on a sheet using toner. A fixing unit includes a first heater that fixes the image to the sheet. A booklet manufacturing unit manufactures a booklet by heating a plurality of sheets that have passed through the fixing unit using a second heater and bonding together the plurality of sheets. Power is supplied to the first heater and the second heater through an inlet. A first detection circuit that detects an inlet current flowing through the inlet. A control circuit controls adjusts the power supplied to the second heater so that the inlet current does not exceed a rated value on a basis of the inlet current detected by the first detection circuit.