Motor Current Control for Consistent Stapleless Binding Force
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Solution Overview
Problem
Conventional stapleless binding methods for sheet bundles in image forming apparatuses face issues with inconsistent pressing force due to variations in actuator output torque, leading to poor binding quality and increased costs for high-strength mechanisms.
Innovation Solution
A sheet processing apparatus with a binding unit, motor, speed detection unit, voltage detection unit, and motor control unit that determines the upper limit of driving current based on detected speed and voltage to maintain consistent pressing force during binding, thereby improving binding quality and reducing size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the output torque of the actuator is increased to ensure adequate pressing force for binding, then the binding quality is improved, but the mechanism size and cost increase due to the need for high-strength materials
Solution Approach 1:
The patent applies dynamics by making the pressing force adjustable through motor control. Instead of using a fixed high-strength mechanism designed for maximum torque, the system dynamically adjusts the motor's driving current to match the actual pressing force needed. This allows the mechanism to be lighter and less expensive while still achieving adequate binding quality when proper pressing force is applied through control.
Solution Approach 2:
The patent changes the electrical parameters (driving current, voltage, speed) of the motor to control the pressing force. By detecting motor speed and voltage and calculating the required driving current, the system adjusts these parameters to maintain appropriate pressing force. This eliminates the need for an oversized mechanical design, reducing both size and cost while maintaining binding quality.
2Reliability
If the pressing force is increased to ensure binding quality, then the binding strength is improved, but the sheets may break due to excessive pressure
Solution Approach 1:
The patent implements feedback by detecting the motor's actual speed and voltage during operation, then using this information to calculate and adjust the driving current. This closed-loop control ensures that the pressing force remains within the optimal range - sufficient to create strong binding through fiber entanglement but not so high as to break the sheets. The system continuously monitors and adjusts to maintain the correct force level.
Solution Approach 2:
The system dynamically adjusts the pressing force based on real-time motor performance characteristics. Rather than applying a fixed high force that might break sheets, the motor control unit adjusts the driving current to achieve the minimum necessary pressing force for quality binding, adapting to variations in motor output and binding requirements.
3Reliability
If a high-strength mechanism is used to ensure adequate pressing force, then the binding quality is improved, but the cost and size of the apparatus increase
Solution Approach 1:
The patent replaces a mechanically complex high-strength pressing mechanism with a controlled motor system. Instead of relying on heavy-duty mechanical components and high-strength materials to guarantee adequate pressing force, the system uses electrical control of motor current to regulate the force applied. This substitution reduces mechanical complexity and cost while maintaining or improving binding quality through precise control.
Solution Approach 2:
The patent changes from a fixed mechanical design to a controllable electrical system. By adjusting motor parameters (driving current, voltage, speed) based on detected performance characteristics, the system achieves the necessary pressing force without requiring an expensive, over-engineered mechanical structure. The control system replaces the need for high-strength, high-cost mechanical components.
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 solution ensures consistent pressing force, enhancing the quality of stapleless binding and reducing the size and cost of the sheet processing apparatus and image forming apparatus by accurately controlling the motor's driving current.
Implementation Method 1
a speed detection unit configured to detect a speed of the motor
Implementation Method 2
a voltage detection unit configured to detect a driving voltage of the motor
Implementation Method 3
a motor configured to drive the binding unit to press the sheet bundle
Data Source
AI summary
A sheet processing apparatus includes a binding unit configured to perform binding processing by pressing a sheet bundle, a motor configured to drive the binding unit to press the sheet bundle, a speed detection unit configured to detect a speed of the motor, a voltage detection unit configured to detect a driving voltage of the motor, and a motor control unit configured to determine an upper limit value of a driving current of the motor based on the speed detected by the speed detection unit and the driving voltage detected by the voltage detection unit in a period when the motor is being driven and the binding unit is not pressing the sheet bundle.