Pickup Roller Motor Phase Detection for Faster First Print
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Solution Overview
Problem
Conventional image forming apparatuses experience increased First Print Output Time (FPOT) due to the time required to estimate the initial position of the rotor in brushless DC motors, which delays the start of image formation on recording media.
Innovation Solution
The image forming apparatus initiates an initial operation to detect the rotor's stop position and phase by supplying current to the motor windings before receiving the instruction to start, allowing for immediate rotation based on the determined phase when the instruction is received, thereby reducing the FPOT.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the initial position estimation operation is performed after the instruction is input to start a job, then the system maintains simplicity and low power consumption, but the First Print Output Time (FPOT) increases
Solution Approach 1:
The system performs the initial position estimation operation in advance during the idle state, before the print job instruction is input. This preliminary action ensures that when the print job starts, the motor is already ready to rotate immediately, thereby reducing the First Print Output Time (FPOT) without affecting normal operation power consumption.
2Productivity
If the initial position estimation operation is performed after the instruction is input to start a job, then the system avoids unnecessary operations during idle state, but the responsiveness and efficiency of the image forming process deteriorate
Solution Approach 1:
The controller executes the initial position estimation operation as a preliminary action during the idle state, before the print job instruction is received. This advance preparation improves the efficiency and responsiveness of the image forming process, as the motor can start rotating immediately when needed, without adding complex control logic.
3Loss of time
If the motor winding is excited continuously to maintain readiness, then the FPOT is minimized, but the power consumption during idle state increases significantly
Solution Approach 1:
Instead of continuously exciting the motor winding during idle state, the system performs a brief initial position estimation operation in advance. This approach achieves minimal FPOT without the need for continuous power consumption, as the motor is prepared only when needed rather than being kept in a continuously excited state.
Solution Approach 2:
The system uses periodic or on-demand initial position estimation operations during idle state rather than continuous winding excitation. This periodic action maintains motor readiness when needed while significantly reducing power consumption during extended idle periods, optimizing the balance between responsiveness and energy efficiency.
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 significantly shortens the FPOT by pre-detecting the rotor's stop position and phase before the print job is initiated, enhancing the efficiency of the image forming process.
Implementation Method 1
determine a phase of the rotor having been in the stop state based on the current flowing through the winding
Implementation Method 2
the controller controls the current to be supplied to the winding such that the rotor having been in the stop state rotates based on the phase determined in the initial operation
Data Source
AI summary
An image forming apparatus includes a stacking unit, a pickup roller, a motor having a winding, a rotor, and a phase, an image forming unit, an operation unit, and a receiving unit. The motor drives the pickup roller to feed a recording medium stacked on the stacking unit. The image forming unit forms an image on the fed medium. A user operates the operation unit to set an image forming condition. When, in a state where the winding is not excited, the operation unit is operated before the receiving unit receives an instruction to start forming the image, an initial operation is executed in a rotor stop state that supplies current to the winding and determines the motor phase based on the current flowing through the winding. When the instruction is received after the initial operation, the winding receives current such that the rotor rotates based on the determined phase.