Image Density Control Using Sensor Feedback
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Solution Overview
Problem
Image forming apparatuses face downtime and density deviations due to environmental changes and component wear, requiring frequent calibration to maintain target density and gradation characteristics, which is time-consuming and inconvenient.
Innovation Solution
An image forming apparatus equipped with a converting unit, image forming unit, sensors for measuring developer and humidity, and a controller that determines image densities based on measured values and generates conversion conditions to predict and adjust image formation settings, reducing the need for frequent calibration by predicting image densities and updating gradation correction tables without forming pattern images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If calibration is executed to maintain target density and gradation characteristics, then image quality is improved, but downtime increases
Solution Approach 1:
The system performs preliminary density measurement using the reflection type density sensor before actual image formation. By measuring the density of a test patch formed on the sheet in advance and using this information to correct image formation conditions, the system avoids the need for time-consuming pattern image formation and measurement that traditional calibration requires
Solution Approach 2:
The invention extracts only the essential measurement function from the traditional calibration process. Instead of forming and measuring complete pattern images, the system uses a reflection type density sensor to measure density characteristics of a simple test patch, extracting the necessary calibration information without the overhead of full pattern image processing
2Manufacturing precision
If frequent calibration is performed to maintain target density, then image quality consistency is improved, but productivity decreases
Solution Approach 1:
The system performs density measurement and condition correction in advance before actual production imaging. The reflection type density sensor measures test patch density quickly, and the controller uses this information to pre-adjust image formation conditions, ensuring consistent quality without interrupting the production flow
Solution Approach 2:
The invention replaces the mechanical pattern image formation and measurement system with an optical reflection type density sensor that measures density characteristics of a test patch. This substitution enables faster, non-contact measurement that does not require forming complete pattern images, thereby maintaining quality consistency while improving productivity
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 allows for maintaining target image densities with reduced downtime by predicting image densities and adjusting settings based on environmental changes, ensuring consistent image quality without the need for frequent calibration, thus shortening the time required to achieve optimal image formation conditions.
Implementation Method 1
a first sensor configured to measure the developer in the image forming unit
Implementation Method 2
a second sensor configured to measure a humidity
Implementation Method 3
a converting unit configured to convert image data based on a conversion condition
Data Source
AI summary
An apparatus converts image data based on a conversion condition, forms an image using a developer, measures the developer, and measures humidity. The apparatus determines a first density of an image when a mode of the apparatus changes from a power saving mode in which the apparatus cannot form an image to a normal mode in which the apparatus can form an image, from values measured, based on a first determination condition, determines a second density of an image when the apparatus has formed images on a predetermined number of sheets in the normal mode, from values measured, based on a second determination condition that is different from the first determination condition, and generates the conversion condition based on the first density and the second density.