Sheet Sorting Controller Using Optical Density Detection
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Solution Overview
Problem
Existing image forming apparatuses face challenges in accurately sorting reusable and non-reusable sheets after a decoloring process, leading to inefficiencies and waste due to incomplete decoloring of images, which results in sheets with remaining images being unsuitable for further use.
Innovation Solution
An image forming apparatus equipped with a reading unit and controller that determines reusability based on image data, using threshold values for maximum density and area ratio of remaining toner, and selectively conveys sheets to either continue the image forming process or discard them, ensuring only reusable sheets are used for printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual sorting of sheets is performed by the user, then sheets can be separated into reusable and non-reusable ones, but it takes significant amount of time and the sorting accuracy is reduced
Solution Approach 1:
The patent replaces the manual mechanical sorting system with an automated optical detection system. The reading unit scans sheets to detect remaining images, and the controller automatically determines reusability based on image density analysis, eliminating the need for manual visual inspection and physical sorting by the user.
Solution Approach 2:
The system enables sheets to self-identify their reusability status through automatic detection. The reading unit and controller work together to automatically classify sheets as reusable or non-reusable based on detected image remnants, allowing the sorting process to serve itself without human intervention.
2Productivity
If decoloring process is carried out on sheets, then sheets can be reused, but the image may not be completely decolored and may partially remain on the sheet
Solution Approach 1:
The patent implements a feedback mechanism where the reading unit detects remaining images on sheets after the decoloring process. The controller analyzes the detected image density and provides feedback to determine whether the sheet has been adequately decolored, allowing for quality control and accurate reusability assessment.
Solution Approach 2:
The system changes the detection parameter from visual inspection to quantitative image density measurement. By measuring the density of remaining images and comparing against threshold values, the system objectively determines decoloring completeness and sheet reusability.
3Productivity
If sheets with remaining images are used for image forming, then productivity is maintained, but image quality deteriorates due to interference from remaining toner
Solution Approach 1:
The patent performs preliminary detection of remaining images on sheets before the image forming process. The reading unit scans and the controller determines reusability in advance, preventing sheets with excessive remaining toner from entering the image forming process, thus ensuring image quality while maintaining productivity.
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 solution enables efficient sorting and reuse of sheets, reducing waste by ensuring only sheets with minimal remaining toner are used for image formation, thereby maintaining image quality and extending the life cycle of decolorable materials.
Implementation Method 1
an image reading unit configured to read a surface of a sheet
Data Source
AI summary
An image forming apparatus includes first and second sheet storages, a sheet conveyer, an image reading unit configured to read a surface of a sheet conveyed from the first sheet storage by the sheet conveyer, an image forming unit configured to form an image on the sheet conveyed from the image reading unit, and a controller. The controller is configured to determine an amount of a color material appearing on the surface of the sheet based on image data generated by the image reading unit, determine one of the image forming unit and the second sheet storage as a sheet feeding destination, based on the determined amount of the color material and a threshold value that is associated with at least one of a type and content of an image to be formed on the sheet, and control the sheet conveyer to convey the sheet to the sheet feeding destination.