Induction Heating Fixing Device Layer Short Detection
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Solution Overview
Problem
Existing induction heating-based fixing devices in image forming apparatuses fail to detect and address 'layer short' issues, leading to improper temperature control and potential device damage, requiring additional sensors and increasing manufacturing costs.
Innovation Solution
A fixing device with a magnetic-flux generation unit, a detector, and a controller that adjusts the switching frequency of the resonant circuit to maintain target power consumption, stopping power supply if a predetermined change width in frequency difference is exceeded, thereby preventing device damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sensors are added to detect layer short conditions, then detection capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The system uses its own existing power consumption detection capability to detect layer short conditions. The controller monitors power consumption of the magnetic-flux generation unit and identifies layer shorts through abnormal power patterns, eliminating the need for separate detection sensors.
Solution Approach 2:
The power consumption detection function serves dual purposes: normal operation monitoring and layer short detection. The same detection mechanism used for general system monitoring is also employed to detect insulation coating defects, making the existing component multi-functional.
2Reliability
If additional sensors are added to detect layer short conditions, then detection capability is improved, but manufacturing cost increases
Solution Approach 1:
The system uses its own existing power consumption detection capability to detect layer short conditions. The controller monitors power consumption of the magnetic-flux generation unit and identifies layer shorts through abnormal power patterns, eliminating the need for separate detection sensors.
Solution Approach 2:
The solution uses inexpensive existing components (power consumption sensors and controller logic) rather than expensive specialized detection sensors. The approach leverages low-cost general-purpose monitoring capabilities to achieve specialized detection functionality.
3Productivity
If the coil continues operating with changed inductance due to layer short, then productivity is maintained, but device reliability deteriorates and further damage occurs
Solution Approach 1:
The system detects layer short conditions before they cause catastrophic failure. By monitoring power consumption and identifying abnormal patterns early, the system takes preventive action to stop operation, preventing further damage to the coil and other components.
Solution Approach 2:
The controller continuously monitors power consumption and uses this feedback to detect layer short conditions. When abnormal power patterns indicating layer shorts are detected, the controller provides feedback to stop operation, preventing further damage while maintaining overall system reliability.
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
Prevents device damage by detecting and addressing layer short conditions without additional sensors, ensuring proper temperature control and reducing manufacturing costs.
Implementation Method 1
a coil that generates a magnetic flux, which causes the heat rotational member to generate heat by induction heating
Implementation Method 2
a magnetic flux generated by the coil passes through metal or the like, and hence heat (Joule heat by eddy current) that is applied to a toner image is obtained
Implementation Method 3
a heating element that generates heat with the alternating magnetic field generated by the alternating magnetic field generating means
Data Source
AI summary
A fixing device includes a heat rotational member that fixes a toner, a pressure rotational member that presses the heat rotational member, a magnetic-flux generation unit, a detector, and a fixing controller. The magnetic-flux generation unit includes a switch unit for switching of power supply to a resonant circuit. The resonant circuit includes a coil that generates a magnetic flux for causing the heat rotational member to generate heat by induction heating, and a capacitor. The detector detects power consumption of the magnetic-flux generation unit. The fixing controller recognizes the power consumption in response to an instruction of target power, sets a switching frequency of the switch unit in accordance with the target power, and causes the switch unit to stop the power supply if a difference between the set switching frequency and the adjusted switching frequency exceeds a predetermined change width.