Ink Residual Estimation for Image Forming Apparatus
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Solution Overview
Problem
Current inkjet image forming apparatuses require costly mechanical sensors to directly measure ink residual amounts in the subtank, leading to high costs and lack of continuous ink residual detection, which limits efficient ink replenishment and printing continuation.
Innovation Solution
The apparatus includes a container residual amount sensor to detect ink empty in the ink container, an ink consumption estimating unit to derive ink consumption values from image data, and a control unit that sets reference values for ink residual estimation, allowing for continuous printing by determining whether the ink residual amount is sufficient for the next page based on tank capacity and regulated amounts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a mechanical sensor is installed to directly measure ink residual amount in the subtank, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces an intermediary calculation method where the control unit estimates ink residual amount by subtracting ink consumption estimation values from the tank capacity. This avoids direct measurement sensors and uses computational logic instead, resolving the contradiction between measurement precision and device complexity
Solution Approach 2:
The patent replaces the mechanical sensor system with an information-processing system. Instead of using physical sensors to detect ink levels, the system uses image data processing and mathematical calculations to determine ink residual amounts, eliminating mechanical complexity while maintaining measurement capability
2Device complexity
If no sensor is installed to detect ink residual amount continuously, then device complexity is reduced, but reliability of printing continuation is worsened
Solution Approach 1:
The patent implements a feedback mechanism where the control unit continuously monitors ink consumption through image data processing and compares it against the estimated ink residual amount. This feedback loop enables reliable determination of whether to continue printing without requiring continuous mechanical sensing
Solution Approach 2:
The system uses its own existing resources (image data processing capability, control unit) to perform ink residual estimation rather than relying on external sensors. The control unit serves itself by using computational methods to monitor ink levels and make printing decisions
3Productivity
If ink replenishment is performed when ink residual amount gets less than regulated amount, then productivity is maintained, but loss of time increases due to frequent replenishment
Solution Approach 1:
The patent applies preliminary action by calculating ink consumption estimation values in advance and using them to predict when ink will be depleted. The control unit proactively determines the optimal replenishment timing based on future ink consumption patterns rather than reacting to current ink levels, reducing unnecessary replenishment interruptions
Data Source
AI summary
In an image forming apparatus, a control unit (a) sets an ink residual estimation value of a subtank as a first reference value corresponding to a tank capacity of the subtank when ink empty is detected on an ink container, and determines whether the ink residual estimation value is less than the ink consumption estimation value of a subsequent page in a print job or not, and (b1) stops the print job if the ink residual estimation value is less than the ink consumption estimation value of the subsequent page and (b2) continues the print job if the ink residual estimation value is equal to or larger than the ink consumption estimation value of the subsequent page.