Image Forming Device with Toner-Adaptive Variable-Interval Quality Adjustment
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Solution Overview
Problem
Image forming devices of the electrophotographic system perform image stabilization control at the same timing regardless of the consumption amount of toner, leading to inappropriate timing for high-density and low-density toner images, and require a toner density sensor, increasing costs.
Innovation Solution
An image forming device that includes a toner container, developing mechanism, image sensor, and controller to calculate a cumulative print rate and adjust developing bias based on image density, performing image quality adjusting processing at varying intervals to determine toner end without a toner density sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If image stabilization control is performed at the same timing constantly, then the control timing is simple to manage, but the image stabilization control cannot be performed at an appropriate timing in accordance with the consumption amount of toner
Solution Approach 1:
The patent applies dynamics by making the image stabilization control interval variable rather than fixed. The control interval is dynamically adjusted based on the cumulative print rate, which reflects toner consumption. When toner consumption is high, the interval shortens to perform stabilization more frequently; when consumption is low, the interval lengthens. This dynamic adjustment resolves the contradiction between simple timing management and adaptability to toner consumption.
2Measurement precision
If a toner density sensor is provided to detect toner amount, then accurate determination of toner end is achieved, but the cost increases
Solution Approach 1:
The patent applies self-service by enabling the image forming device to determine toner end conditions using its own existing resources rather than external sensors. The system uses the image sensor (already present for image quality detection) and cumulative print rate data (already tracked for accounting) to infer toner consumption and determine when toner is depleted. This eliminates the need for additional toner density sensors while maintaining accurate detection capability.
Solution Approach 2:
The patent applies universality by making the image sensor serve multiple functions: it detects both image density for quality control and toner amount for end-of-toner determination. The cumulative print rate calculation system also serves dual purposes of billing/accounting and toner consumption monitoring. This multi-functionality allows accurate toner detection without adding dedicated sensors.
3Stability of the object's composition
If image quality adjusting processing is performed frequently, then image density stability is improved, but the frequency of interruption of image forming processing increases
Solution Approach 1:
The patent applies dynamics by making the image quality adjusting processing interval variable based on toner consumption levels. Instead of frequent fixed-interval adjustments that interrupt productivity, the system dynamically extends the interval when toner is abundant and reduces it when toner is depleted. This ensures image density stability is maintained when needed while minimizing interruptions 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
Reduces the frequency of image forming interruptions and accurately determines toner end at appropriate times, ensuring stable image quality without the need for a toner density sensor, thus reducing costs.
Implementation Method 1
an image sensor that detects an image density of the toner image
Implementation Method 2
a developing mechanism that forms a toner image on a surface of an image carrier using the toner supplied from the toner container
Implementation Method 3
the toner image transferred to the printing sheet is heated and melted by a fixing device and fixed to the sheet
Data Source
AI summary
A controller executes, at a first interval, which is a predetermined interval, first processing of performing only the image quality adjusting processing in a first period, which is a period until the first cumulative print rate exceeds a predetermined first reference value and the first image quality adjusting processing is performed, and performs the image quality adjusting processing at a second interval shorter than the first interval and executes second processing of performing determining processing by using the remaining amount determining processor in a second period, which is a period after a time point at which the image quality adjusting processing is executed first time after the first cumulative print rate exceeds the first reference value.