Load Cell Toner Level Sensing in Image Formers

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Solution Overview

Problem

Current systems fail to accurately distinguish between full and low-toner cassettes in image forming apparatuses, leading to potential damage and image quality defects, as existing methods like shaking the cassette to redistribute toner are inefficient and may result in air being pulled instead of a steady toner volume, and toner level estimation is based on average consumption without considering additional toner requirements.

Innovation Solution

Incorporating a load cell in the developer station to sense the mass of the toner cassette, allowing the processor to determine the toner volume and control the operation of the image forming apparatus, with a controller driving or suspending the motor based on the detected toner level, thereby preventing damage and ensuring optimal printing conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If operators shake the cassette to redistribute toner, then the toner may be redistributed for continued operation, but this may lead to air being pulled instead of steady toner volume and potential damage to stations

Engineering Contradiction:

Improveoperational continuityVSAvoidstation damage risk

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The load cell performs preliminary detection of toner cassette weight before printing operations begin. The system proactively identifies low-toner conditions and alerts operators in advance, allowing them to replace cassettes before damage occurs, rather than reacting after damage has happened during shake-up attempts

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors toner cassette weight via the load cell and provides real-time feedback to both the controller and operator interface. This feedback loop enables the system to track toner consumption patterns and alert operators when weight indicates low toner levels, preventing the need for dangerous shake-up operations

Inventive Principle:

Principle #23Feedback

2Measurement precision

If toner level is estimated based on average consumption, then the system can track toner usage, but the estimate does not match actual volume when additional toner is required

Engineering Contradiction:

Improvetoner level estimationVSAvoidtoner consumption variability

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The system transitions from estimating toner levels based on average consumption parameters to directly measuring the physical parameter of toner cassette weight using a load cell. This weight measurement provides accurate real-time data about actual toner volume regardless of consumption patterns or image complexity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the software-based estimation system (which calculated toner levels from sheet counts and average consumption) with a direct mechanical measurement system using a load cell. This physical measurement approach eliminates the inaccuracies inherent in mathematical estimation models

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the image forming apparatus operates on low-level toner, then printing may continue, but carrier beads may damage the photoreceptor drum surface

Engineering Contradiction:

Improveprinting continuityVSAvoiddrum surface damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The load cell system performs preliminary detection of low-toner conditions before damage can occur. By identifying weight changes indicating low toner levels in advance, the system enables proactive prevention measures (operator alerts, printing suspension) that stop the harmful process before carrier beads can damage the photoreceptor drum

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The continuous weight monitoring provides real-time feedback about toner cassette status. When the load cell detects weight corresponding to low toner levels, the system immediately feedbacks this information to the controller and operator interface, enabling timely intervention to prevent drum damage while maintaining productivity

Inventive Principle:

Principle #23Feedback

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

The system effectively differentiates between full and low-toner cassettes, preventing damage to the apparatus and ensuring consistent image quality by accurately determining the toner volume and controlling the print operation, thereby extending the life of the equipment and maintaining image quality.

Implementation Method 1

a load cell positioned in a developer station. The load cell is adapted to sense a mass of a toner cassette

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS8472819B2Toner bottle presence and level sensing using weight

Publication Date: 2013.06.25 XEROX CORP

AI summary

An image forming apparatus is adapted to distinguish a presence between a full and a partially-full toner cassette. The image forming apparatus includes a load cell positioned in a developer station. The load cell is adapted to sense a mass of a toner cassette at least during an insertion of the toner cassette into the apparatus. A processor is adapted to determine a toner volume contained in the toner cassette based on a mass differential. A controller is adapted to drive or suspend a motor in the developer station to control an operation of the image forming apparatus. The controller controls the operation based on the toner volume.