Image Forming Motor Control for Phase-Aligned Transfer Contact
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Solution Overview
Problem
Existing image forming apparatuses face issues with increased power consumption and improper image formation due to imprecise adjustment of motor control modes, particularly when switching from vector control to constant current control, leading to misalignment of rotating components.
Innovation Solution
The image forming apparatus incorporates a controller that switches control modes from constant current control to vector control based on rotor speed, using a phase determiner to adjust motor control, ensuring precise alignment of rotating components and reducing power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the control mode is switched from vector control to constant current control when the rotor speed exceeds a predetermined value, then power consumption is reduced, but the rotation phase of the rotor may lead the target phase by 360° or more causing improper image formation
Solution Approach 1:
The patent implements feedback control by continuously monitoring the rotation phase of the rotor and adjusting the control mode switching decision based on the detected phase difference. The phase difference calculation unit computes the phase difference between the actual rotation phase and target phase, and this feedback information is used to determine whether to switch from vector control to constant current control, ensuring that the switching does not cause the rotation phase to lead the target phase by 360° or more.
Solution Approach 2:
The patent performs preliminary calculation of the phase difference before switching control modes. By calculating the expected phase difference in advance and comparing it with the threshold value, the system determines whether switching to constant current control would cause improper image formation. This preliminary action prevents harmful effects by avoiding mode switching when the phase difference would exceed acceptable limits.
2Manufacturing precision
If vector control is used to maintain precise rotation phase control, then image formation accuracy is improved, but power consumption increases
Solution Approach 1:
The patent dynamically adjusts the control mode based on real-time operating conditions. The control unit switches between vector control and constant current control modes depending on the detected rotation phase and phase difference. When precise control is needed, vector control is applied; when power consumption is more critical and phase difference is within acceptable limits, constant current control is used. This dynamic adaptation resolves the contradiction by optimizing the balance between image formation accuracy and power consumption.
Solution Approach 2:
The patent changes the control parameter (control mode) based on the rotation phase and phase difference conditions. By monitoring the phase difference and comparing it with a predetermined threshold, the system switches between different control modes to optimize both image formation accuracy and power consumption. This parameter change approach allows the system to maintain precision when necessary while reducing energy consumption when possible.
3Use of energy by moving object
If constant current control is used to reduce power consumption, then energy efficiency is improved, but the rotor may go out of synchronization with input signals causing step-out state
Solution Approach 1:
The patent uses feedback control to monitor the rotation phase continuously and determine the appropriate control mode. By calculating the phase difference between actual and target phases and using this feedback information, the system switches between vector control and constant current control. This feedback mechanism ensures that constant current control is only applied when it will not cause the rotor to go out of synchronization, thus maintaining reliability while achieving energy efficiency.
Solution Approach 2:
The patent performs preliminary assessment of the phase difference before applying constant current control. By calculating the expected phase difference in advance and comparing it with the threshold, the system determines whether switching to constant current control would cause step-out. This preliminary action prevents synchronization loss by avoiding constant current control when the phase difference would exceed safe limits.
Data Source
AI summary
An image forming apparatus includes a photosensitive member, an intermediate transfer member, a moving member, a driving motor, a stepper motor, a detector, a phase determiner, and a controller. The stepper motor drives the moving member to move between a first position at which the photosensitive member contacts the intermediate transfer member and a second position at which the photosensitive member contacts the intermediate transfer member are separated. The controller includes a first control mode to control a motor based on a predetermined current magnitude and a second control mode to control a motor by vector control. The controller starts driving the driving motor in the first control mode, and then switches from the first control mode to the second control mode. The controller controls the stepper motor in the first control mode during a period from when the stepper motor is activated to when the stepper motor is stopped.