Stepping Motor Current Control for Noise Reduction
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Solution Overview
Problem
In image forming apparatuses using stepping motors, the constant-current drive system often results in excessive motor output, leading to increased noise, energy consumption, and heat generation due to surplus energy production, which necessitates additional components like cooling mechanisms and complicates manufacturing by requiring more components.
Innovation Solution
An image forming apparatus with a controller that detects changes in load torque and adjusts the current value supplied to the stepping motor based on the detected load torque, optimizing motor output and reducing energy consumption by setting the appropriate current value dynamically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high constant-current value is set to ensure motor operation under maximum load torque, then the motor can operate without step out even under maximum load, but the motor produces excessive output during normal operation causing increased noise, energy consumption, and heat generation
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant-current drive system to a dynamic control system that adjusts current based on actual load conditions. The controller monitors motor operation state and dynamically changes current values between a first current value for normal operation and a second current value for maximum load, allowing the system to adapt to varying load requirements and avoid excessive output during normal operation.
Solution Approach 2:
The patent implements parameter changes by varying the current parameter based on load torque conditions. The controller detects when the motor is operating under maximum load torque and switches between different current values (first current value for normal operation, second current value for maximum load). This parameter adjustment allows the motor to maintain reliability under maximum load while reducing noise and energy consumption during normal operation.
2Reliability
If a high constant-current value is set to prevent step out under maximum load torque, then the motor can handle sudden load increases, but energy consumption increases due to surplus energy production
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant-current drive system to a dynamic control system that adjusts current based on actual load conditions. The controller monitors motor operation state and dynamically changes current values between a first current value for normal operation and a second current value for maximum load, allowing the system to adapt to varying load requirements and avoid excessive output during normal operation.
Solution Approach 2:
The patent implements parameter changes by varying the current parameter based on load torque conditions. The controller detects when the motor is operating under maximum load torque and switches between different current values (first current value for normal operation, second current value for maximum load). This parameter adjustment allows the motor to maintain reliability under maximum load while reducing noise and energy consumption during normal operation.
3Reliability
If a high constant-current value is set to ensure motor operation under maximum load, then the motor can operate reliably, but heat generation increases requiring additional cooling mechanisms
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant-current drive system to a dynamic control system that adjusts current based on actual load conditions. The controller monitors motor operation state and dynamically changes current values between a first current value for normal operation and a second current value for maximum load, allowing the system to adapt to varying load requirements and avoid excessive output during normal operation.
Solution Approach 2:
The patent implements parameter changes by varying the current parameter based on load torque conditions. The controller detects when the motor is operating under maximum load torque and switches between different current values (first current value for normal operation, second current value for maximum load). This parameter adjustment allows the motor to maintain reliability under maximum load while reducing noise and energy consumption during normal operation.
4Reliability
If a high constant-current value is set to prevent step out, then the motor can handle maximum load conditions, but the apparatus complexity increases due to additional cooling mechanisms
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant-current drive system to a dynamic control system that adjusts current based on actual load conditions. The controller monitors motor operation state and dynamically changes current values between a first current value for normal operation and a second current value for maximum load, allowing the system to adapt to varying load requirements and avoid excessive output during normal operation.
Solution Approach 2:
The patent implements parameter changes by varying the current parameter based on load torque conditions. The controller detects when the motor is operating under maximum load torque and switches between different current values (first current value for normal operation, second current value for maximum load). This parameter adjustment allows the motor to maintain reliability under maximum load while reducing noise and energy consumption during normal operation.
5Reliability
If a high constant-current value is set to ensure motor operation under maximum load, then the motor can operate without step out, but manufacturing costs increase due to additional components
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant-current drive system to a dynamic control system that adjusts current based on actual load conditions. The controller monitors motor operation state and dynamically changes current values between a first current value for normal operation and a second current value for maximum load, allowing the system to adapt to varying load requirements and avoid excessive output during normal operation.
Solution Approach 2:
The patent implements parameter changes by varying the current parameter based on load torque conditions. The controller detects when the motor is operating under maximum load torque and switches between different current values (first current value for normal operation, second current value for maximum load). This parameter adjustment allows the motor to maintain reliability under maximum load while reducing noise and energy consumption during normal operation.
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 noise, energy consumption, and the need for cooling mechanisms, while also simplifying the apparatus by minimizing unnecessary components, thus enhancing efficiency and reducing manufacturing costs.
Implementation Method 1
a motor driving part for supplying power to drive the stepping motor
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
When a printing instruction is provided, a CPU (13) causes a stepping motor M to drive a developer and calculates the value of a load of the stepping motor M before printing operations are performed. Then, CPU (13) determines whether the value of the load is within a predetermined range stored in advance. If the value is not within the predetermined range, CPU (13) causes a display (50) to display an error message.