Image Forming System Defect Localization Using Vibration Analysis
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Solution Overview
Problem
Existing techniques for diagnosing defects in image forming apparatuses often fail to accurately identify the causal replaceable component, leading to increased time in resolving defects.
Innovation Solution
An image forming system that includes an image forming apparatus and a server capable of communication. The system collects operation data from the apparatus, detects defects, and identifies the location of defects within specific ranges of replaceable components, allowing for precise reporting of potential causal parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing diagnostic techniques are used to detect defects in image forming apparatuses, then defects can be detected, but the causal replaceable component cannot be accurately identified, leading to increased time in resolving defects
Solution Approach 1:
The patent segments the image forming apparatus into multiple replaceable components (drum unit, toner cartridge, transfer roller unit, etc.) and further divides each component into specific parts (drum, cleaner blade, charging roller, etc.). By collecting vibration data from multiple sensors positioned at different locations and analyzing which specific component generates the abnormal vibration pattern, the system achieves precise localization of the defective part, enabling accurate identification of the causal replaceable component and reducing troubleshooting time.
2Reliability
If multiple replaceable components are included in the diagnostic range, then the likelihood of identifying the causal part increases, but the complexity of the diagnostic system increases
Solution Approach 1:
The patent implements a universal diagnostic system that can handle multiple types of defects across different replaceable components using a single integrated approach. The vibration collection unit with multiple sensors, the centralized data processing system, and the pattern matching algorithm work together to diagnose various defects (abnormal vibrations, image quality issues, conveyance problems) in different components (drum, transfer roller, cleaner blade, etc.) through one unified system, avoiding the need for separate diagnostic systems for each component type.
Solution Approach 2:
The patent introduces vibration sensors as intermediary devices that mediate between the mechanical operations of multiple replaceable components and the diagnostic analysis system. These sensors convert physical vibrations from various components into electrical signals that can be processed and analyzed, serving as an intermediary layer that simplifies the diagnostic process while maintaining the ability to monitor multiple components simultaneously.
3Measurement precision
If detailed data collection from multiple sources is performed, then defect identification accuracy improves, but the amount of data to be processed increases
Solution Approach 1:
The patent extracts only the relevant vibration data from the collected information by comparing it against pre-stored vibration patterns specific to each replaceable component and defect type. Instead of processing all raw data from multiple sensors, the system extracts and analyzes only those vibration characteristics that match known defect patterns, significantly reducing the effective data volume that requires detailed processing while maintaining high diagnostic accuracy.
Solution Approach 2:
The patent performs preliminary action by pre-storing vibration patterns and characteristics of normal and defective states for each replaceable component before actual operation. This pre-established database allows the system to quickly compare real-time sensor data against known patterns, enabling rapid identification of defects without needing to process and analyze all raw data from scratch, thus reducing the computational burden while maintaining precision.
Data Source
AI summary
The server includes: an identification unit configured to identify that a location of a defect is in a first range including a plurality of replaceable components in an image forming apparatus, and in a case where it is possible to identify that the location of the defect is in a second range included in the first range, further identify the second range; and a reporting unit configured to, in a case where the identification unit identifies the second range, report to a display apparatus such that the display apparatus displays information indicating the second range, and in a case where the identification unit does not identify the second range, report to the display apparatus such that the display apparatus displays information indicating the first range.