Printer Power Consumption Estimation Using Pre-characterized Mode Data
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Solution Overview
Problem
Accurately estimating the power consumption of devices like xerographic printers is challenging due to the need to measure AC voltage, current, and compensate for power factor and harmonics, especially at low power levels, making it costly and complex to design measuring circuitry.
Innovation Solution
Pre-characterizing energy use in different modes of operation, such as active, ready, and sleep, and using a computing device with processor-executable instructions to calculate power consumption based on pre-measured data, including time spent in each mode, without requiring expensive measuring hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If expensive measurement circuitry is used to accurately measure AC voltage, current, power factor, and harmonics, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent pre-characterizes power consumption data during device manufacturing by measuring voltage, current, power factor, and harmonics for each operational mode. This preliminary characterization creates lookup tables stored in memory that enable accurate power estimation during operation without requiring complex real-time measurement circuitry. The complex measurement work is performed once during manufacturing rather than continuously during device operation.
Solution Approach 2:
The patent creates simplified copies of the complex measurement system by using pre-measured data tables that replicate the information would provide if actual measurement circuitry were present. Instead of implementing physical voltage and current sensors with signal conditioning circuits, the system uses stored characterization data that copies the essential power consumption information for each operational state, eliminating the need for expensive measuring hardware while maintaining measurement accuracy.
2Measurement precision
If complex measurement circuitry is implemented to compensate for power factor and harmonics, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent performs the complex measurement and compensation calculations during the manufacturing process, creating pre-characterization data tables that capture power consumption for each operational mode. This shifts the manufacturing complexity from the end product to the manufacturing process itself, allowing the final device to use simple microcontroller-based calculations with pre-stored data, thereby reducing manufacturing costs while maintaining measurement accuracy.
Solution Approach 2:
The patent replaces expensive, complex measurement circuitry with inexpensive microcontroller-based calculations using pre-stored data. The system uses a low-cost microcontroller that reads operational state from sensors and looks up corresponding power consumption values in pre-characterized tables, achieving accurate power measurement without the need for costly voltage/current sensors, signal conditioning circuits, and digital signal processing hardware.
3Adaptability or versatility
If measurement circuitry is designed for wide power range, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent characterizes power consumption across the entire operational range during manufacturing, creating comprehensive lookup tables that cover all possible power states from sleep to full operation. This preliminary action captures the full adaptability requirement in pre-stored data, allowing the device to handle any power level using simple table lookups rather than requiring complex circuitry designed to accommodate the full power range.
Solution Approach 2:
The patent divides the continuous power consumption range into discrete operational modes (sleep, ready, active, etc.), with each mode having its own pre-characterized power consumption data. This segmentation allows the system to use simple discrete state detection and corresponding lookup table entries rather than requiring complex continuous measurement circuitry that could accurately measure and interpret the full range of power states.
Data Source
AI summary
Examples disclosed herein relate to receiving a usage report from a printer, wherein the usage report comprises a count of pages printed and a time spent in a first power state; calculating a power consumption for the printer according to the usage report, and providing a report of historic power consumption.