Ink Level Detection Using Dot Counting Thresholds
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Solution Overview
Problem
Existing liquid consumption devices, such as inkjet printing systems, face challenges in accurately detecting when ink levels fall below a predetermined amount due to sensor faults or malfunctions, leading to inaccurate ink consumption calculations.
Innovation Solution
A liquid consumption device with a sensor, fault finding section, and determination section that calculates a threshold value based on estimated consumption amounts and theoretical values, allowing for accurate detection of ink levels even when the sensor is faulty, using a statistical method to evaluate and update threshold values for different liquid container capacities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a sensor is used to detect ink levels, then detection speed is improved, but reliability deteriorates due to sensor faults
Solution Approach 1:
The system performs preliminary actions by calculating threshold values based on dot counting data before sensor faults occur. The control section accumulates ink consumption amounts through dot counting and calculates threshold values in advance, so that when a sensor fault is detected, the system can immediately switch to using the pre-calculated threshold values for accurate ink level determination.
Solution Approach 2:
The system uses feedback by comparing sensor detection results with threshold values derived from dot counting data. The control section continuously monitors ink consumption through dot counting, compares it with sensor readings, and adjusts the threshold values accordingly. This feedback mechanism ensures that even when the sensor fails, the system can detect ink levels accurately using the accumulated consumption data.
2Reliability
If dot counting method is used to estimate ink consumption, then reliability is improved, but measurement precision deteriorates
Solution Approach 1:
The system changes parameters by transforming dot counting data (number of discharges) into ink consumption amounts using predetermined ink amounts per discharge. The control section calculates cumulative consumption amounts from discharge counts and uses these calculated values as threshold levels, thereby converting discrete counting data into continuous measurement equivalents that achieve both reliability and precision.
Solution Approach 2:
The system performs preliminary calculation of threshold values based on dot counting data before actual ink level detection is needed. By accumulating consumption amounts and calculating threshold values in advance, the system prepares precise reference values that can be directly used for accurate ink level determination without requiring real-time sensor corrections.
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
Enables high-accuracy detection of ink levels and estimation of remaining ink quantity, even with faulty sensors, by using calculated threshold values that reflect the ratio of estimated to theoretical consumption amounts, ensuring reliable operation across various liquid container capacities.
Implementation Method 1
light is incident with regard to a bottom surface of a prism (a surface which opposes the apex of the prism) which is provided in the ink cartridge, the intensity of light, which is reflected from the prism which changes according to the presence or absence of ink at the reflecting surface of the prism, is detected
Data Source
AI summary
A liquid consumption device includes a replaceable liquid container, a sensor, a fault finding section, an estimation section and a determination section. The sensor detects whether or not liquid has reached a predetermined amount. The fault finding section finds whether there is a fault in the sensor. The estimation section calculates an estimated value of a consumption amount of the liquid. The determination section carries out determination based on the estimated value of the liquid container and a threshold value which is specified based on threshold value information when a fault in the sensor has been found. The determination section carries out the determination based on the sensor when a fault in the sensor has not been found and to calculate the threshold value information based on the estimation value when the sensor detects that the liquid has reached the predetermined amount.