Image Carrier Circumference Measurement Using Waveform Matching
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Solution Overview
Problem
Conventional image forming apparatuses face challenges in accurately measuring the circumference of an image carrier, leading to errors in image density calibration, increased downtime, and higher costs due to the need for optical detection marks and sensors, as well as excessive toner consumption and potential inaccuracies in unstable belt travel conditions.
Innovation Solution
An image forming apparatus and method that acquire first and second waveform data from the image carrier's surface using a detector, calculate the circumference based on matching between the two datasets, and determine the reliability of the calculated information to recalculate if necessary, reducing downtime and toner usage while maintaining accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mark and optical sensor are used to measure the circumference of the image carrier, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The image carrier itself serves as the measurement target by utilizing its inherent image patterns rather than requiring external marks. The detector reads images formed on the image carrier surface, and the control unit calculates circumference from these readings, allowing the system to measure using its own operational components without additional measurement infrastructure.
Solution Approach 2:
The system uses optical copies (images) that are naturally formed on the image carrier during normal operation as the measurement reference. Instead of physical marks, the pattern of images transferred to the image carrier serves as the measurement target, eliminating the need for separate marking and detection components.
2Measurement precision
If the image carrier rotates multiple rounds to measure circumference, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The system performs preliminary readings during the first rotation of the image carrier to establish baseline data. By pre-acquiring image data at multiple positions during initial rotation, the control unit can calculate circumference without requiring complete additional rotations, thus reducing total measurement time while maintaining precision.
Solution Approach 2:
The system acquires more image readings than the absolute minimum required by obtaining data at multiple positions during a single rotation cycle. This partial excess of measurement data allows the control unit to perform more robust calculations and verify results, improving precision without proportionally increasing measurement time.
3Productivity
If waveform data is acquired from unstable belt travel conditions, then productivity is improved, but measurement precision deteriorates
Solution Approach 1:
The control unit continuously monitors the detected image waveforms for consistency and reliability indicators. When waveform data shows signs of instability or inconsistency, the system automatically triggers a recalculation using additional readings. This feedback mechanism ensures that only reliable data is used for circumference calculation, maintaining precision even when productivity requirements demand faster operation.
Solution Approach 2:
The measurement system dynamically adapts its operation based on detected conditions. When unstable belt travel is detected through waveform analysis, the system automatically adjusts by performing additional measurements and recalculations. This dynamic response allows the system to maintain measurement precision under varying operational conditions without requiring constant manual intervention.
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 approach allows for precise and efficient circumference measurement, minimizing downtime and toner consumption, and ensuring accurate image density calibration by dynamically adjusting for variations in the image carrier's circumference, thereby enhancing the usability and cost-effectiveness of the apparatus.
Implementation Method 1
an optical sensor receives light reflected by a mark to measure the circumference of an image carrier
Data Source
AI summary
There is provided an image forming apparatus including a rotation member used for image forming and a detector for detecting light from the rotation member. First waveform data of an image-formed surface used to form an image on the rotation member is acquired by the detector. Second waveform data of the image-formed surface used to form an image on the rotation member is acquired. The second waveform data includes at least part of a detected section of the first waveform data. Information on the actual circumference of the rotation member is calculated based on matching between the acquired first and second waveform data. The acquired first waveform data and second waveform data are compared to determine whether or not to use the calculated information on the circumference. When it is determined not to use the calculated information on the circumference, information on the circumference of the rotation member is recalculated.