Imaging Device Media Sensor Dual-Intensity LED Test
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Solution Overview
Problem
The existing media-full sensor in imaging devices fails when the LED breaks, causing the device to stop operating, as a broken LED is indistinguishable from a full media bin condition, leading to unnecessary service interruptions.
Innovation Solution
A method is implemented where the imaging device emits a light beam at two intensity levels to determine if the media-full sensor is functioning correctly, allowing the device to continue operating if the sensor fails, by trusting the output only when the higher intensity beam is detected, thus enabling a 'soft fail' scenario.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-intensity light beam is used in the media-full sensor, then the device structure is simple, but the sensor cannot distinguish between a broken LED and a full media bin condition
Solution Approach 1:
The patent applies partial action by using two different intensity levels (first intensity and second intensity greater than first) to test the sensor. Instead of using a single intensity level, the system performs multiple tests at different intensities to determine whether the sensor is responding correctly, thereby distinguishing between a broken LED and a full bin condition.
Solution Approach 2:
The patent changes the parameter of light intensity by emitting light beams at two different intensity levels. This parameter change allows the system to observe different responses from the photo-transistor, enabling it to determine whether the sensor is functioning properly or if the LED is broken, thus resolving the ambiguity in sensor readings.
2Reliability
If the imaging device stops operation when the media-full sensor fails, then the sensor can be given full attention for repair, but the device experiences unnecessary service interruptions and productivity loss
Solution Approach 1:
The patent implements self-service by enabling the imaging device to continue operating even when the media-full sensor fails. The controller is programmed to detect sensor failures through the dual-intensity light beam test and automatically adjust its behavior to ignore the faulty sensor readings, allowing the device to self-diagnose and self-adjust without requiring immediate service intervention.
Solution Approach 2:
The patent applies beforehand cushioning by implementing a preventive test mechanism that detects LED failures before they cause actual media-full misreadings. By continuously testing the sensor response at two intensity levels, the system cushions against the harmful effects of sensor failure by anticipating and compensating for potential reading errors before they disrupt operations.
3Measurement precision
If the LED emits light at high intensity continuously, then the photo-transistor receives sufficient light signal, but the LED generates excessive heat and fails more quickly
Solution Approach 1:
The patent applies periodic action by using pulsed light emission at two different intensity levels rather than continuous emission. The controller periodically tests the sensor response at the first intensity level, then at the second (higher) intensity level, creating a rhythmic testing pattern that reduces cumulative heat buildup while still achieving accurate sensor verification through the periodic high-intensity pulses.
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
This approach allows the imaging device to continue operating even if the media-full sensor fails, preventing paper jams and service interruptions, while ensuring accurate detection of media levels by using a dual-intensity light beam to verify sensor functionality.
Implementation Method 1
The LED emits an infrared beam that with the media bin not full reaches the photo-transistor actuating the photo-transistor to change its state
Implementation Method 2
The LED and photo-transistor are typically positioned transverse to the media path. The LED emits an infrared beam that with the media bin not full reaches the photo-transistor actuating the photo-transistor to change its state
Data Source
AI summary
A method of operating an imaging device having a failed or failing media-full sensor determines whether or not a controller can trust the output signal received from the media-full sensor. A reduced power or intensity level is used to test the media-full sensor and, in particular, the light source to counter the dimming of the light source that occurs due to aging and electrical noise in the system. When the output signal of a photoreceptor is at or below a threshold value, the photo-receptor is considered to have not detected the light beam from the light source and the light beam is deemed not to have been detected even though the photo-receptor may be providing a lower level output signal. Thus, an output signal of the photo-receptor is not trusted and an indication that a media storage area is not full is provided and an imaging operation is carried out.