Slip Amount Prediction Controller for Image Forming Apparatus
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Solution Overview
Problem
In image forming apparatuses using electrophotography, sheet feeding issues lead to slipages and jams due to wear of feeding rollers, resulting in wasted sheets and toner, and decreased productivity.
Innovation Solution
An image forming apparatus with a slip amount prediction controller that calculates the predicted slip amount between the sheet feeder and sheet, adjusting the image forming timing to synchronize sheet feeding and toner image transfer, thereby preventing jams and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If feeding rollers are used to convey sheets, then sheet feeding function is achieved, but sheet slip and jam occur due to roller wear
Solution Approach 1:
The system performs preliminary measurement of the sheet feeder's conveying capability by detecting the actual sheet position during feeding operations. This measured slip amount is then used to predict future slip conditions and adjust image forming timing accordingly, preventing jams before they occur.
Solution Approach 2:
The system continuously monitors the actual position of sheets during feeding and compares it with expected positions to calculate slip amounts. This feedback information is stored and used to predict future slip conditions, allowing dynamic adjustment of image forming timing to maintain synchronization between sheet feeding and image transfer.
2Manufacturing precision
If registration roller pair is used to synchronize sheet feeding, then timing synchronization is achieved, but sheet feeding delays occur due to temporary stopping
Solution Approach 1:
The system dynamically adjusts the image forming timing based on actual measured slip amounts from sheet feeding. Instead of using fixed timing synchronization, the system continuously adapts the timing offset to compensate for varying slip conditions, eliminating the need for temporary stops while maintaining synchronization accuracy.
3Device complexity
If fixed image forming timing is used, then image forming process is simple, but sheet feeding delays cause jams
Solution Approach 1:
The system changes the timing parameter of image forming based on measured slip amounts from sheet feeding. By adjusting the timing offset according to actual feeding conditions, the system prevents jams caused by synchronization failures while maintaining a relatively simple control structure that builds upon existing timing mechanisms.
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
The solution effectively reduces sheet feeding delays and jams, minimizing waste and maintaining high productivity by accurately synchronizing sheet feeding and toner image transfer.
Implementation Method 1
forms an electrostatic latent image on a photoconductor by light exposure to the photoconductor
Implementation Method 2
forms a toner image by developing the electrostatic latent image with a developer such as toner
Implementation Method 3
transfers the toner image to a sheet
Data Source
AI summary
An image forming apparatus includes an image bearer, an image forming device to form an image on the image bearer, a transfer device to transfer the image formed on the image bearer onto a sheet, a storage to store the sheet, a sheet feeder to convey the sheet one by one to the transfer device, and a slip amount prediction controller. The slip amount prediction controller calculates a predicted slip amount between the sheet feeder and the sheet before forming the image and, subsequently calculates an interval between images based on the predicted slip amount. The slip amount prediction controller controls the image forming device based on the calculated interval between images to form the image on the image bearer.