Sheet Heater Control Using Adaptive Power Levels
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Solution Overview
Problem
Conventional sheet heating devices experience temperature overshooting during startup and image processing, leading to unnecessary power consumption and potential image fixation failures due to excessive heater temperatures.
Innovation Solution
A sheet heating device with a control unit that sets initial power supply levels based on previous heating job data and adjusts power supply levels using temperature feedback to maintain target temperatures, employing upper and lower power limits for different temperature ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a large amount of electric power is supplied to the heater during start-up to quickly raise the temperature, then the heater temperature rises quickly to the predetermined temperature, but the heater temperature may overshoot because the heater temperature at start-up may be higher than its normal powered-off temperature
Solution Approach 1:
The power supply level is dynamically adjusted based on the detected heater temperature. The control unit selects from multiple power supply levels (first, second, third levels) depending on whether the temperature is below the lower limit, between limits, or above the upper limit, making the heating process adaptive rather than static
Solution Approach 2:
A temperature sensor detects the heater temperature in real-time and feeds this information back to the control unit, which then adjusts the power supply level accordingly. This closed-loop feedback mechanism prevents overshooting by reducing power when the temperature approaches the target range
2Reliability
If a large amount of electric power is supplied to the heater to perform image fixing or image decoloring, then the heating process is effective, but the heater temperature may overshoot causing melted toner to remain on sheets and sheets to adhere to each other
Solution Approach 1:
The temperature sensor continuously monitors the heater temperature during image fixing and decoloring operations, providing real-time feedback to the control unit. When the temperature exceeds the upper limit, the control unit reduces the power supply level, preventing toner overheating and sheet adhesion
Solution Approach 2:
The system changes the power supply parameter dynamically by selecting from multiple discrete power levels based on temperature conditions. This allows precise control of heating intensity to maintain reliability while avoiding harmful overheating effects
3Loss of time
If a large amount of electric power is supplied to the heater during start-up, then the heater reaches operational temperature quickly, but unnecessary power consumption occurs due to temperature overshooting
Solution Approach 1:
The power supply level transitions from high initial power to lower maintenance power dynamically as the heater temperature increases. The control unit adjusts power levels based on real-time temperature detection, optimizing the balance between quick warm-up and energy efficiency
Solution Approach 2:
The heating process occurs in distinct phases with different power levels: an initial high-power phase for rapid heating, followed by a reduced-power phase for temperature maintenance. This periodic adjustment of power supply reduces overall energy consumption while maintaining quick response
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 reduces power consumption and prevents overheating, ensuring accurate temperature control and preventing issues like sheet adhesion and image fixation failures by dynamically managing power supply levels.
Implementation Method 1
a sheet heating device which supplies a large amount of electric power to a heater to quickly raise a temperature thereof
Implementation Method 2
a temperature sensor configured to detect a temperature of the heater
Data Source
AI summary
A sheet heating device includes a heater, a power supply for the heater, and a control unit configured to set an initial power supply level of the power supply at a start of a sheet heating job by the heater based on the sheet heating job and according to whether or not maximum and minimum power supply levels from a last sheet heating job are stored, and control the power supply level of the power supply during the sheet heating job based on a temperature detected by the temperature sensor.