Heating Roller Temperature Control for Fuser Systems
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Solution Overview
Problem
Existing image forming apparatuses face challenges in accurately controlling the temperature of heating rollers to prevent toner offset, paper curl, and energy inefficiency, particularly due to limitations in sensor placement and type, which affect image quality and fuser lifespan.
Innovation Solution
An image forming apparatus with a heating roller configuration using a central and side heater unit, controlled by sensors positioned in notification and non-notification areas, employing a controller to adjust heating values based on temperature differences and target temperatures, and turning off heaters when overheating is detected, to maintain optimal temperature and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a contacting temperature sensor is used to measure the temperature of the heating roller, then the material cost is reduced, but image deterioration occurs due to temperature difference between the contacted and non-contacted portions
Solution Approach 1:
The heating roller temperature measurement is segmented into multiple measurement points. A first temperature sensor measures the temperature at a first position (e.g., central notification area) and a second temperature sensor measures the temperature at a second position (e.g., side notification area). This segmentation allows different regions of the heating roller to be monitored independently, preventing image deterioration while using cost-effective contacting sensors.
Solution Approach 2:
The controller acts as an intermediary that processes temperature data from multiple sensors and determines appropriate heating control strategies. By introducing this intermediary processing layer, the system can compensate for the limitations of contacting sensors and maintain image quality without requiring expensive non-contacting sensors throughout.
2Manufacturing precision
If the temperature of the nip part is increased to improve fusing, then the fusing quality improves, but toner hot offset occurs and paper curl increases
Solution Approach 1:
Different target temperatures are applied to different regions of the heating roller based on local requirements. The controller determines a first target temperature for a first heater unit (e.g., central region) and a second target temperature for a second heater unit (e.g., side region). This local quality approach allows optimal fusing in each region while preventing hot offset and excessive paper curl, as each region's temperature is independently optimized.
Solution Approach 2:
The system dynamically adjusts temperature parameters based on real-time measurements and printing conditions. By changing the target temperature parameters for different heater units according to actual temperature readings and paper width, the system achieves optimal fusing quality while avoiding the harmful effects of excessive temperature such as hot offset and paper curl.
3Stability of the object's composition
If multiple heater units are used to heat different regions of the heating roller, then temperature distribution improves, but the control complexity increases
Solution Approach 1:
The heating system is segmented into multiple independent heater units (e.g., first heater unit for central region, second heater unit for side regions). Each heater unit can be controlled independently based on temperature measurements from corresponding sensors, improving temperature distribution while maintaining manageable control complexity through modular design.
Solution Approach 2:
The control system manages complexity by dynamically adjusting temperature parameters for different heater units based on actual operating conditions. The controller determines appropriate target temperatures for each heater unit based on paper width, temperature readings, and predefined relationships, allowing adaptive control without requiring overly complex control algorithms.
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 precise temperature control of the heating rollers, reducing toner offset, paper curl, and energy wastage, while improving image quality and extending fuser lifespan by effectively managing temperature across the heating roller surface.
Implementation Method 1
a heating roller heated using a first heater unit placed in a center thereof and second heater units placed on both sides of the first heater unit
Implementation Method 2
a first sensor detecting a temperature of a central area of the heating roller; a second sensor detecting the temperature of a side area of the heating roller
Implementation Method 3
a recording medium on which the transfer is performed passes through a fuser to fuse the toner image on the recording medium
Data Source
AI summary
An image forming apparatus as provided includes: a heating roller heated using a first heater unit disposed in the center thereof and second heater units disposed on both sides of the first heater unit; a pressure roller in pressing contact with the heating roller to form a nip; first and second sensors for detecting the temperature of a central area of the heating roller the temperature of a side area of the heating roller, respectively; and a controller for individually controlling the first and second heater units according to the respective temperatures measured by the first and second sensors when the temperature measured by the second sensor is lower than a predetermined first temperature, and commonly controlling the first and second heater units according to the temperature measured by the first sensor when the temperature measured by the second sensor is equal to or higher than the predetermined first temperature.