Toner Adhesion Calculation in Image Forming Apparatus
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Solution Overview
Problem
Image forming apparatuses face accuracy issues in estimating toner adhesion when dots are formed overlappingly on other dots, as the adhesion of toner is more difficult in such cases, leading to a deterioration in the estimation of toner adhesion amount.
Innovation Solution
The apparatus includes a first storage section for dot pattern data, a dot forming section, a forming-dot counting section, an overlapping-dot counting section, and a calculating section. The calculating section calculates the toner adhesion amount by subtracting the estimated amount of non-adhering toner from the estimated adhering toner, where the non-adhering toner is estimated based on the number of overlapping dots, and different non-adhesion coefficients are used for each color to account for varying toner adhesion depending on the color of the overlapping dots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dots are formed overlappingly on other dots that are already formed, then the image forming apparatus can create complex multi-color images, but the accuracy of estimating toner adhesion amount deteriorates
Solution Approach 1:
The patent segments the toner adhesion estimation into two distinct components: dots formed directly on the recording medium and dots formed overlappingly on other dots. By separately counting and estimating adhesion for each type, the system resolves the accuracy deterioration caused by treating all dots uniformly, while maintaining the capability to form complex multi-color overlapping images.
2Device complexity
If the same estimation method is used for all dots regardless of overlap, then the calculation process remains simple, but the toner adhesion amount estimation becomes inaccurate for overlapping dots
Solution Approach 1:
The patent applies local quality by differentiating the estimation approach based on the local condition of each dot. Dots are categorized into those formed on the recording medium and those formed overlappingly on other dots, with separate adhesion estimation calculations applied to each category. This localized differentiation improves accuracy without requiring complete recalculation of all dots, thus balancing complexity and precision.
3Measurement precision
If dot pattern data for all colors is stored in memory simultaneously, then overlapping dot detection is accurate, but storage capacity is consumed
Solution Approach 1:
The patent performs preliminary action by storing dot pattern data for previously formed colors in memory before forming the current color dots. This allows accurate detection of overlapping dots by comparing current dot positions with stored previous color patterns. After the current color is formed, the stored data for previous colors can be cleared, enabling accurate overlapping detection while managing storage capacity through sequential data retention.
Data Source
AI summary
A forming-dot counting section counts a number of dots of a subject color based on dot pattern data of the subject color. An overlapping-dot counting section compares the dot pattern data of the subject color and the dot pattern data of at least one other color of which dots are formed prior to the subject color, and counts a number of overlapping dots of the subject color that are formed in an overlapping relation with the dots of the at least one other color. A calculating section calculates the amount of adhering toner of the subject color by subtracting an estimated amount of non-adhering toner from an estimated amount of adhering toner. The estimated amount of adhering toner is estimated based on the number of dots of the subject color. The estimated amount of non-adhering toner is estimated based on the number of overlapping dots.