Ink Level Detection in Image Recording Apparatus
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Solution Overview
Problem
In liquid droplet ejecting apparatuses, the existing systems fail to accurately determine the remaining ink amount in the sub-tank, leading to premature cartridge replacement and potential ejection failures due to air flow when ink is depleted.
Innovation Solution
An image recording apparatus with a cartridge and a tank system that includes sensors and a controller to monitor liquid levels, activating notifications and controlling liquid discharge to determine the remaining ink amount in both the cartridge and sub-tank with high precision, preventing air flow and optimizing ink usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cartridge is replaced when the ink level in the cartridge reaches a predetermined amount, then the ejection failure is prevented, but the ink remaining in the sub-tank is wasted and the cartridge is replaced prematurely
Solution Approach 1:
The ink storage system is divided into two separate containers: a cartridge with a first liquid chamber for initial ink storage and a sub-tank with a second liquid chamber for additional ink storage. This segmentation allows independent monitoring and management of ink levels in each container, enabling the system to continue using ink from the sub-tank even when the cartridge is depleted, thereby preventing premature cartridge replacement and reducing ink waste.
Solution Approach 2:
The system employs sensors to continuously monitor ink levels in both the cartridge and sub-tank, providing real-time feedback to the control unit. Based on this feedback, the control unit accurately determines when the ink is depleted and notifies the user at the optimal time for cartridge replacement, preventing both premature replacement and ejection failures caused by ink depletion.
2Quantity of substance
If the cartridge is used until the ink is completely depleted, then the ink usage is maximized, but air flows into the recording head causing ejection failure
Solution Approach 1:
The system performs preliminary detection of ink depletion by monitoring the ink level in the cartridge using a sensor. When the ink level reaches a predetermined threshold, the control unit notifies the user in advance before the ink is completely depleted. This preliminary action allows the user to replace the cartridge before air enters the recording head, preventing ejection failure while maximizing ink usage.
Solution Approach 2:
The sensor continuously provides feedback on the ink level in the cartridge to the control unit. This feedback mechanism enables the system to accurately determine when the ink is depleted and notify the user at the optimal time, preventing both premature cartridge replacement and ejection failures caused by ink depletion.
3Measurement precision
If a sensor is installed to detect ink level in the sub-tank, then the remaining ink amount is determined with high precision, but the device complexity increases
Solution Approach 1:
The sensor installed in the cartridge serves a dual function: it detects the ink level in the cartridge (first liquid chamber) and, through fluid communication with the sub-tank (second liquid chamber), also provides information about the ink level in the sub-tank. This multi-functionality allows the system to determine the remaining ink amount with high precision without installing separate sensors in both containers, thereby reducing device complexity.
Solution Approach 2:
The fluid communication pathway between the cartridge and sub-tank acts as an intermediary, allowing the sensor in the cartridge to indirectly detect the ink level in the sub-tank. This intermediary mechanism enables the system to monitor ink levels in both containers using a single sensor, avoiding the need for additional sensors and reducing device complexity while maintaining measurement precision.
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
The image recording apparatus has a head, a tank, a case that receives a cartridge, and a controller. When the cartridge is installed in the case of the image recording apparatus, the liquid in the cartridge flows to the tank by a difference between a liquid level in the cartridge and a liquid level in the tank. The controller controls a display to display a first notification indicating an ink cartridge based on receiving a first signal output from a sensor when a liquid level in an ink chamber reached a specific position. The controller, after receiving the first signal from the sensor, counts a count value indicating an amount of discharged liquid from the head. Further, the controller, in response to the count value reaching a first threshold, controls the display to display a second notification.