Image Forming Apparatus Process Condition Determination
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Solution Overview
Problem
Image forming apparatuses face challenges in accurately determining process conditions due to sensor measurement saturation when the amount of toner exceeds a predetermined amount, leading to lower calibration accuracy and failure to expand the color gamut effectively.
Innovation Solution
The apparatus forms multiple pattern images with varying parameters and uses linear interpolation within monotonic increase regions to determine target density values, excluding non-monotonic regions to accurately set process conditions, thereby overcoming measurement saturation issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the amount of toner is increased to expand color gamut, then the single-color maximum density increases, but the sensor measurement result becomes saturated
Solution Approach 1:
The patent divides the measurement process into multiple segments by creating multiple measurement images with different toner amounts. Instead of relying on a single saturated measurement, the system segments the toner application into controlled portions that keep each individual measurement within the sensor's linear range, thereby avoiding saturation while still achieving high maximum density through cumulative effect or selective use of measurement data.
Solution Approach 2:
The patent changes the parameters of the measurement process by varying the toner amount across multiple measurement images. By adjusting the toner concentration and distribution parameters in each measurement image, the system ensures that at least some measurements fall within the sensor's accurate measurement range, allowing determination of process conditions without saturation interference.
2Measurement precision
If multiple measurement images are formed to determine process condition, then calibration accuracy improves, but the complexity of the calibration process increases
Solution Approach 1:
The patent makes the measurement images serve multiple functions: they are used both for visual inspection/validation purposes and for automated sensor-based measurement. This multi-functionality allows the same set of images to provide both qualitative and quantitative data, improving calibration accuracy without requiring entirely separate measurement systems or processes.
Solution Approach 2:
The patent implements feedback mechanisms where the sensor measurements from multiple measurement images are processed to determine optimal process conditions, which then feed back into the image forming process. The system uses the measurement results to adjust and refine the process conditions iteratively, improving calibration accuracy through closed-loop control while automating the complexity management.
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 determination of process conditions even when measurement results are saturated, ensuring accurate calibration and expanding the color gamut of image forming apparatuses.
Implementation Method 1
A possible cause of the saturation of the measurement result is that, when the amount of pigment included in the toner is greater than or equal to a predetermined amount, light cannot pass through or reflect off the measurement image.
Data Source
AI summary
An image forming unit forms a plurality of measurement images based on a plurality of process conditions. A measurement unit measures the density of each of the plurality of measurement images. A determination unit uses a first determination mode or a second determination mode. In the first determination mode, a process condition is determined from a first measurement result higher than target density and a second measurement result lower than the target density, from among a plurality of measurement results. In the second determination mode, the process condition is determined from measurement results lower than the target density.