Sheet Feed Roller State Detection via Drive Load Fluctuation
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Solution Overview
Problem
Conventional image forming apparatuses face challenges in accurately detecting the amount of paper dust on rollers, leading to unnecessary cleaning and replacement, which reduces productivity due to misalignment and wear, as existing methods like current waveform analysis and PWM duty ratio averaging are insufficient for determining the actual state of the sheet feed roller.
Innovation Solution
An image forming apparatus equipped with a hardware processor that detects the fluctuation range of the load applied to the drive source, allowing for precise determination of the roller's state by analyzing the drive current fluctuations, thereby optimizing cleaning and replacement schedules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If periodic cleaning of the sheet feed roller is performed to reduce sheet misfeeding, then sheet feeding reliability is improved, but productivity decreases due to unnecessary cleaning operations and apparatus unavailability
Solution Approach 1:
The patent replaces the conventional mechanical cleaning system with an optical detection system. A light source and light receiver detect paper dust on the sheet feed roller by measuring light scattering, eliminating the need for periodic mechanical cleaning operations and their associated productivity losses
Solution Approach 2:
The sheet feed roller's paper dust accumulation state is automatically detected through optical measurement, enabling the system to self-monitor and trigger cleaning only when necessary, rather than following a fixed periodic schedule that causes unnecessary downtime
2Reliability
If frequent cleaning is performed to maintain roller performance, then sheet misfeeding is reduced, but the roller life is shortened due to surface wear
Solution Approach 1:
The patent replaces mechanical cleaning with optical detection, allowing the roller to operate until actual paper dust accumulation is detected. This eliminates unnecessary mechanical cleaning cycles that cause wear, thereby extending roller life while maintaining reliable sheet feeding
Solution Approach 2:
The cleaning frequency is made dynamic and condition-based rather than fixed. The system continuously monitors roller surface state through optical detection and performs cleaning only when paper dust accumulation reaches a threshold, optimizing the balance between reliability and component life
3Difficulty of detecting and measuring
If conventional current waveform analysis is used to detect roller state, then detection capability is provided, but measurement precision is insufficient to distinguish actual paper dust accumulation from other load variations
Solution Approach 1:
The patent replaces electrical measurement (current waveform analysis) with optical measurement (light scattering detection). The light source and receiver directly measure paper dust on the roller surface, providing precise detection that distinguishes actual dust accumulation from other sources of load variation
Solution Approach 2:
The patent introduces light as an intermediary to detect paper dust. The light source illuminates the roller surface and the light receiver measures scattered light, which directly correlates with paper dust accumulation, providing a precise measurement intermediary that eliminates the indirect and imprecise current-based detection
Data Source
AI summary
An image forming apparatus includes: a drive source that drives an object; and a hardware processor that detects a fluctuation range of a load applied to the drive source by driving the object, and determines a state of the object on a basis of a detection result.